IllustrationSEATBELT BUCKLE PIECE POPPED OUT AND I HAVE TO PUSH THE RED BUTTON TO SECURE SEATBELT.
2002 Toyota Tundra
Owner reports · Recalls · Investigations
More warning signs than most Tundra years
Owner complaints for the 2002 Toyota Tundra are substantially higher than the model-year median of 144.5.
About this comparison →How this year compares
Owner complaints by model year
Compare all Tundra years →Counts vary with age, sales and reporting. They are not failure rates.
What owners reported most
All reported categories
Tap a category to read its complaints. One report may name several components.
When problems were reported
Mileage at the reported incident
530–25K
4425–50K
5350–75K
5475–100K
87100–150K
79150K+
370 reports with mileage · 112 unknown
NHTSA’s mileage field refers to the reported incident, not necessarily the filing date. This shows report counts, not the likelihood of a failure.
What to inspect
Issues worth paying extra attention to based on owner reports.
- Structure. Review the 154 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Service Brakes, Hydraulic. Review the 97 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Suspension. Review the 81 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
NHTSA owner reports · September 18, 2026 snapshot.
30 crash reports1 fire reports16 injury reports
What owners actually said
482 reportsREPLACED BALL JOINTS 4 TIMES IN 10 YEARS
TL* THE CONTACT OWNS A 2002 TOYOTA TUNDRA. WHILE THE VEHICLE WAS AT AN INDEPENDENT MECHANIC FOR MAINTENANCE, THE CONTACT WAS INFORMED THAT THE REAR CROSS MEMBERS ON BOTH SIDES AND THE FRAME WERE SEVERELY CORRODED AND NEEDED REPLACEMENT. THE VEHICLE WAS NOT TAKEN TO THE DEALER FOR DIAGNOSTIC TESTING. THE MANUFACTURER WAS NOT NOTI…
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TL* THE CONTACT OWNS A 2002 TOYOTA TUNDRA. WHILE THE VEHICLE WAS AT AN INDEPENDENT MECHANIC FOR MAINTENANCE, THE CONTACT WAS INFORMED THAT THE REAR CROSS MEMBERS ON BOTH SIDES AND THE FRAME WERE SEVERELY CORRODED AND NEEDED REPLACEMENT. THE VEHICLE WAS NOT TAKEN TO THE DEALER FOR DIAGNOSTIC TESTING. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE VEHICLE WAS NOT REPAIRED. THE APPROXIMATE FAILURE MILEAGE WAS 86,000.
FRAME IS RUSTED AND WON'T PASS INSPECTION. HAVE ALREADY REPLACED FENDER AND BOX
"TOYOTA RECALLS" CHASIS/FRAME - I HAD EVERY RECALL OR SERVICE BULLETIN COMPLETED BY TOYOTA SALES/SERVICE IN OUR AREA. TOYOTA'S FIX FOR THE FRAME RUST DID NOT WORK. I WAS INFORMED THIS WEEK THAT THERE ARE NOW HOLES IN THE FRAME. THE TAILGATE IS RUSTING ALONG WITH THE BED OF THE TRUCK AS I WAS ABLE TO SEE THE UNDERNEATH OF THE BED…
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"TOYOTA RECALLS" CHASIS/FRAME - I HAD EVERY RECALL OR SERVICE BULLETIN COMPLETED BY TOYOTA SALES/SERVICE IN OUR AREA. TOYOTA'S FIX FOR THE FRAME RUST DID NOT WORK. I WAS INFORMED THIS WEEK THAT THERE ARE NOW HOLES IN THE FRAME. THE TAILGATE IS RUSTING ALONG WITH THE BED OF THE TRUCK AS I WAS ABLE TO SEE THE UNDERNEATH OF THE BED WHEN THE TOYOTA DEALERSHIP PUT IT UP ON THE HOSIT YESTERDAY. THIS TRUCK HAS BEEN MAINTAINED PROPERLY, HAS APPROXIMATELY 135,000 MILES ON IT, AND THE BODY IS STILL IN GOOD CONDITION. ALTHOUGH I WAS NOTIFIED THIS WEEK ABOUT THE FRAME, IT'S HAS BEEN ON GOING FOR SOME TIME AND I DO NOT UNDERSTAND WHY NO ONE IN THE LAST 2 YEARS INFORMED US OF THE FRAME RUST DAMAGE. EVEN THE TOYOTA SERVICE DEPARTMENT THAT HAD SERVICED THE VEHICLE EARLIER THIS YEAR DID NOT INFORM ME OF THE EXTENT OF FRAME RUST DAMAGE.
TL* THE CONTACT OWNS A 2002 TOYOTA TUNDRA. UPON INSPECTING THE VEHICLE, THE CONTACT NOTICED THAT THE REAR DIFFERENTIAL WAS LEAKING. THE CONTACT ALSO MENTIONED THAT THE CHAIN THAT HELD THE SPARE TIRE IN PLACE FRACTURED FROM THE FRAME. THE VEHICLE WAS TAKEN TO BROWN'S TOYOTA OF GLEN BURNIE (7167 RITCHIE HWY, GLEN BURNIE, MD 21061 …
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TL* THE CONTACT OWNS A 2002 TOYOTA TUNDRA. UPON INSPECTING THE VEHICLE, THE CONTACT NOTICED THAT THE REAR DIFFERENTIAL WAS LEAKING. THE CONTACT ALSO MENTIONED THAT THE CHAIN THAT HELD THE SPARE TIRE IN PLACE FRACTURED FROM THE FRAME. THE VEHICLE WAS TAKEN TO BROWN'S TOYOTA OF GLEN BURNIE (7167 RITCHIE HWY, GLEN BURNIE, MD 21061 (410) 761-9000) WHERE THE CONTACT WAS INFORMED THAT THE REAR AXLE NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS APPROXIMATELY 81,000.
2002 TOYOTA TUNDRA SR5 FRAME WAS SPRAYED WITH UNDERCOATING PER RECALL WHEN IT SHOULD HAVE BEEN REPLACED. NOW FRAME HAS HOLES 1" WIDE 4" LONG BEHIND FRONT TIRES ON BOTH SIDES. BODY STILL LOOKS NEW. I SEE TRUCKS FOR SALE THAT ARE RUSTED OUT BEYOND REPAIR BUT HAVE NEW FRAMES.
TL* THE CONTACT OWNS A 2002 TOYOTA TUNDRA. THE CONTACT STATED THAT THERE WAS EXTENSIVE RUST AND CORROSION PERTAINING TO THE FRAME. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE VEHICLE WAS NOT INCLUDED IN NHTSA CAMPAIGN NUMBERS: 09V444000 (STRUCTURE) AND 05V225000 (SUSPENSION). THE CONTACT WAS UNCERTAIN IF THE FAILURES WERE REL…
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TL* THE CONTACT OWNS A 2002 TOYOTA TUNDRA. THE CONTACT STATED THAT THERE WAS EXTENSIVE RUST AND CORROSION PERTAINING TO THE FRAME. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE VEHICLE WAS NOT INCLUDED IN NHTSA CAMPAIGN NUMBERS: 09V444000 (STRUCTURE) AND 05V225000 (SUSPENSION). THE CONTACT WAS UNCERTAIN IF THE FAILURES WERE RELATED TO THE RECALL CAMPAIGNS. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURES AND INDICATED THAT THE BUY BACK OPTION AND FRAME REPLACEMENT EXTENDED CAMPAIGN ENDED IN 2012 AND THERE WAS NO REMEDY. THE FAILURE MILEAGE WAS NOT AVAILABLE.
I PURCHASED THIS TRUCK USED IN 2015 AND WAS UNAWARE OF ANY RECALLS DUE TO FRAME RUST. I HAVE REPLACED TAILPIPE, MUFFLER, MANY BRAKE COMPONENTS DUE TO RUST PROBLEMS. THE FRAME NOW RUSTED MORE AND I AM BEING TOLD THAT IT MAY BE UNSAFE TO DRIVE. A MECHANIC TOLD ME ABOUT THIS FRAME RUST RECALL AND I TOOK IT TO FRED ANDERSON TOYOTA I…
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I PURCHASED THIS TRUCK USED IN 2015 AND WAS UNAWARE OF ANY RECALLS DUE TO FRAME RUST. I HAVE REPLACED TAILPIPE, MUFFLER, MANY BRAKE COMPONENTS DUE TO RUST PROBLEMS. THE FRAME NOW RUSTED MORE AND I AM BEING TOLD THAT IT MAY BE UNSAFE TO DRIVE. A MECHANIC TOLD ME ABOUT THIS FRAME RUST RECALL AND I TOOK IT TO FRED ANDERSON TOYOTA IN RALEIGH,NC. THE FOUND THAT ALL RECALL ITEMS HAD BEEN COMPLETED BY THE DEALER IN BOONE,NC. I FIND THIS HARD TO BELIEVE SINCE THE RUSTING ISSUE IS MUCH MORE SEVERE. I JUST WANT A FAIR EVALUATION OF WHAT CAN OR SHOULD BE DONE. FRED ANDERSON TOYOTA IN RALEIGH DID HAVE THE TRUCK BUT NOT SURE HOW FAR THEY TOOK THE INVESTIGATION OF RUST.
THE CHASSIS OF THE TRUCK IS VERY DAMAGED BY RUST, IN SOME PARTS IT EVEN HAS HOLES, SO I DO NOT KNOW IF IT IS VERY SAFE TO HANDLE IT. I BOUGHT IT AT A CAR DEALER A FEW WEEKS AGO, I THOUGHT IT WAS JUST A BIT OF RUST ... BUT WHEN I CHECKED IT OUT BETTER I NOW FIND THAT THE RUST REALLY HARMS THE STRUCTURE, ANOTHER PROBLEM ... IT GI…
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THE CHASSIS OF THE TRUCK IS VERY DAMAGED BY RUST, IN SOME PARTS IT EVEN HAS HOLES, SO I DO NOT KNOW IF IT IS VERY SAFE TO HANDLE IT. I BOUGHT IT AT A CAR DEALER A FEW WEEKS AGO, I THOUGHT IT WAS JUST A BIT OF RUST ... BUT WHEN I CHECKED IT OUT BETTER I NOW FIND THAT THE RUST REALLY HARMS THE STRUCTURE, ANOTHER PROBLEM ... IT GIVES OFF A STRONG SMELL OF GASOLINE. ..
Official recalls
309V444000 · Structure:frame And Members:underbody Shields
Nov 18, 2009
TOYOTA IS RECALLING MODEL YEAR 2000-2003 TUNDRA VEHICLES ORIGINALLY SOLD IN OR CURRENTLY REGISTERED IN THE FOLLOWING STATES: CONNECTICUT, DELAWARE, ILLINOIS, INDIANA, KENTUCKY, MAINE, MARYLAND, MASSACHUSETTS, MICHIGAN, MINNESOTA, NEW HAMPSHIRE, NEW JERSEY, NEW YORK, OHIO, PENNSYLVANIA, RHODE ISLAND, VERMONT, VIRGINIA, WEST VIRGINIA, WISCONSIN AND THE DISTRICT OF COLUMBIA. EXCESSIVE CORROSION OF THE REAR CROSS MEMBER MAY CAUSE THE SEPARATION OF THE SPARE TIRE STOWED UNDER THE TRUCK BED WHICH WOULD PRESENT A ROAD HAZARD THAT COULD CAUSE A CRASH. ALSO, CORROSION OF THE REAR CROSS MEMBER COULD AFFECT THE REAR BRAKE LINES AND THE PROPORTIONING VALVE RESULTING IN DIMINISHED BRAKING CAPABILITY.
Consequence & remedy
Consequence: SEPARATION OF THE SPARE TIRE AND DIMINISHED BRAKE CAPACITY COULD INCREASE THE RISK OF A CRASH.
Remedy: TOYOTA IS ASKING OWNERS OF THE AFFECTED VEHICLES TO REMOVE THE SPARE TIRE FROM UNDER THE VEHICLE UNTIL A REMEDY CAN BE OBTAINED. DEALERS WILL INSPECT THE REAR CROSS MEMBER AND RELATED COMPONENTS, INCLUDING THE BRAKE LINES, AND REPLACE THEM IF NECESSARY. IF THE CROSS MEMBER DOES NOT NEED TO BE REPLACED, IT WILL BE SPRAYED WITH A CORROSION PROTECTION COMPOUND. THESE SERVICES WILL BE PERFORMED FREE OF CHARGE, HOWEVER MULTIPLE VISITS TO THE DEALER MAY BE REQUIRED. THE SAFETY RECALL IS EXPECTED TO BEGIN ON OR ABOUT APRIL 30, 2010. OWNER MAY CONTACT TOYOTA AT 1-800-331-4331.
05V225000 · Suspension:front:control Arm:lower Ball Joint
May 17, 2005
ON CERTAIN SPORT UTILITY VEHICLES, DUE TO A MANUFACTURING ISSUE IN THE FRONT SUSPENSION LOWER BALL JOINT, THERE IS A POSSIBILITY THAT THE SURFACE OF THE BALL OF THE JOINT MAY HAVE BEEN SCRATCHED. THE BALL JOINT MAY EVENTUALLY EXPERIENCE EXCESSIVE WEAR AND LOOSENESS, RESULTING IN INCREASED STEERING EFFORT.
Consequence & remedy
Consequence: THE LOWER BALL JOINT MAY SEPARATE FROM THE KNUCKLE CAUSING LOSS OF STEERING CONTROL AND A CRASH COULD OCCUR.
Remedy: DEALERS WILL REPLACE THE FRONT SUSPENSION LOWER BALL JOINTS FREE OF CHARGE. THE RECALL BEGAN ON JULY 5, 2005. OWNERS MAY CONTACT TOYOTA AT 1-800-331-4331.
02V129000 · Wheels
May 1, 2002
ON CERTAIN 4X2 VEHICLES EQUIPPED WITH AN ALLOY WHEEL TIRE UPGRADE (OPTIONS WM4, WM8, ZL1-ZL4, DH4, OR DH5) INSTALLED BY THE PROCESSING CENTERS IN JACKSONVILLE, FLORIDA OR COMMERCE, GEORGIA, A LABEL IDENTIFYING THE SPARE TIRE AS A TEMPORARY USE SPARE TIRE WAS NOT INSTALLED. THE UPGRADE INCLUDES 4 LARGER SIZE TIRES WITH ALLOY WHEELS. THE ORIGINAL SPARE TIRE/STEEL WHEEL IS NOT PART OF THE UPGRADE AND WAS NOT CHANGED.
Consequence & remedy
Consequence: DIFFERENT OPERATING CHARACTERISTICS CAN BE EXPERIENCED WHEN THE SPARE TIRE IS INSTALLED ON THE VEHICLE.
Remedy: OWNERS WILL BE PROVIDED WITH A CAUTION LABEL AND AN INSERT FOR THEIR OWNER'S MANUAL. OWNER NOTIFICATION BEGAN JULY 15, 2002. OWNERS WHO DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT SOUTHEAST TOYOTA AT 1-800-301-6859.
Model-level recall history does not show whether a particular VIN is affected or has received a repair. Check a VIN with NHTSA ↗
NHTSA investigations
3PE09049 · Frame Corrosion
Opened Oct 6, 2009 · Closed Jan 26, 2010
Status: closed (inferred from source dates) · Fuel System, Gasoline; Fuel System, Gasoline:storage:tank Assembly; Fuel System, Gasoline:storage:tank Assembly:mounting; Service Brakes, Hydraulic; Service Brakes, Hydraulic:foundation Components:differential Proportional Valve; Service Brakes, Hydraulic:foundation Components:hoses, Lines/piping, And Fittings; Structure:frame And Members; Tires:temporary/emergency Spare Tire
THIS INVESTIGATION WAS OPENED BASED ON 20 REPORTS OF MODEL YEAR (MY) 2000 AND 2001 VEHICLES EXPERIENCING SEVERE CORROSION OF THE FRAME, RESULTING IN EITHER UNDER-BODY MOUNTED SPARE TIRE SEPARATION OR REAR BRAKE FAILURE.THE FAILURE REPORT COUNTS SHOWN ABOVE ARE FOR MY 2000 AND 2001 VEHICLES ONLY.BY LETTER OF NOVEMBER 16, 2009 TOYOTA HAS NOTIFIED THE AGENCY THAT IT WILL CONDUCT A SAFETY RECALL (09V-444) OF APPROXIMATELY 110,000 MODEL YEAR (MY) 2000 THROUGH 2003 TUNDRA VEHICLES.THE AFFECTED RECALLED VEHICLES WERE SOLD OR ARE CURRENTLY REGISTERED IN THE DISTRICT OF COLUMBIA AND THE STATES OF CT, DE, IL, IN, KY, MA, MD, ME, MI, MN, NH, NJ, NY, OH, PA, RI, VA, VT, WI, WV.TOYOTA ALLEGES HIGH AMOUNTS OF ROAD SALTS ARE USED IN THESE AREAS AND EXCESSIVE CORROSION OF THE REAR CROSS-MEMBER (TO WHICH THE SPARE TIRE IS MOUNTED) CAN OCCUR AND CAUSE THE SPARE TIRE TO SEPARATE FROM THE VEHICLE AND CAN ALSO LEAD TO REAR BRAKE FAILURE.TOYOTA STATED: TOYOTA HAS TENTATIVELY CONCLUDED THAT THE ROOT CAUSE IS A COMBINATION OF FACTORS, INCLUDING USAGE IN AREAS WHERE ROAD SALT IS APPLIED, INADEQUATE VEHICLE MAINTENANCE (I.E., NOT FOLLOWING THE RECOMMENDATIONS IN THE OWNER'S MANUAL), THE DESIGN OF THE REAR CROSS-MEMBER, AND MANUFACTURING ISSUES.THE DESIGN OF THE REAR CROSS-MEMBER IS SUCH THAT IT IS OPEN ON THE TOP SIDE AND SUSCEPTIBLE TO ACCUMULATION OF DIRT, WATER AND ROAD SALT.MANUFACTURING ISSUES OF THE REAR CROSS-MEMBER RELATED TO THE COATING PROCESS ALSO AFFECT ITS CORROSION RESISTANCE.TOYOTA ALSO STATES THAT OWNERS OF MY 2000 THROUGH 2003 VEHICLES IN STATES NOT COVERED BY THE RECALL WILL BE NOTIFIED ON HOW TO OBTAIN THE SAME INSPECTION AND REPAIR AS THE RECALLED VEHICLES, FREE OF CHARGE.FURTHER TOYOTA STATES: PLEASE NOTE THAT WHILE TOYOTA HAS NOT DETERMINED A DEFECT EXISTS IN 2004 THROUGH 2006 MY TUNDRA VEHICLES, TOYOTA PLANS ON INITIATING A FIELD ACTION IN THE NEAR FUTURE TO PREVENT FUTURE CORROSION ON THOSE VEHICLES ORIGINALLY SOLD OR CURRENTLY REGISTERED IN THE AFFECTED REGION AT NO COST TO THE OWNER.BY LETTER OF JANUARY 8, 2010 TOYOTA HAS NOTIFIED THE AGENCY THAT IT AMENDED ITS DEFECT INFORMATION REPORT FOR SAFETY RECALL 09V-444 TO INCLUDE THE FUEL TANK MOUNTING SYSTEM (I.E., FUEL TANK SUPPORT STRAPS AND FUEL TANK MOUNTING CROSS-MEMBERS) IN THE SAFETY RECALL.TOYOTA STATES: TOYOTA HAS NOT DECIDED THAT THE FUEL TANK MOUNTING SYSTEM IN THOSE VEHICLES CONTAINS A SAFETY-RELATED DEFECT WITHIN THE MEANING OF FEDERAL MOTOR VEHICLE SAFETY LAW.RATHER, TOYOTA IS TAKING THIS ACTION AT ODI'S REQUEST AND TO AVOID FUTURE DISAGREEMENT WITH ODI WITH RESPECT TO THIS ISSUE.MY 2007 AND NEWER TUNDRA VEHICLES ARE NOT INCLUDED IN ANY OF TOYOTA'S ACTIONS AS THE REAR CROSS-MEMBER IN THOSE VEHICLES HAVE BEEN REDESIGNED SO THAT IT IS OPEN ON THE BOTTOM.THE ACTIONS TAKEN BY TOYOTA ARE SUFFICIENT TO RESOLVE THE ISSUES RAISED BY THIS INVESTIGATION.ACCORDINGLY, THIS INVESTIGATION IS CLOSED.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT A SAFETY-RELATED DEFECT DOES NOT EXIST IN THE SUBJECT VEHICLES.THE AGENCY WILL TAKE FURTHER ACTION IF WARRANTED BY THE CIRCUMSTANCES.
Additional source detail variants (8)
Fuel System, Gasoline:storage:tank Assembly:mounting
THIS INVESTIGATION WAS OPENED BASED ON 20 REPORTS OF MODEL YEAR (MY) 2000 AND 2001 VEHICLES EXPERIENCING SEVERE CORROSION OF THE FRAME, RESULTING IN EITHER UNDER-BODY MOUNTED SPARE TIRE SEPARATION OR REAR BRAKE FAILURE.THE FAILURE REPORT COUNTS SHOWN ABOVE ARE FOR MY 2000 AND 2001 VEHICLES ONLY.BY LETTER OF NOVEMBER 16, 2009 TOYOTA HAS NOTIFIED THE AGENCY THAT IT WILL CONDUCT A SAFETY RECALL (09V-444) OF APPROXIMATELY 110,000 MODEL YEAR (MY) 2000 THROUGH 2003 TUNDRA VEHICLES.THE AFFECTED RECALLED VEHICLES WERE SOLD OR ARE CURRENTLY REGISTERED IN THE DISTRICT OF COLUMBIA AND THE STATES OF CT, DE, IL, IN, KY, MA, MD, ME, MI, MN, NH, NJ, NY, OH, PA, RI, VA, VT, WI, WV.TOYOTA ALLEGES HIGH AMOUNTS OF ROAD SALTS ARE USED IN THESE AREAS AND EXCESSIVE CORROSION OF THE REAR CROSS-MEMBER (TO WHICH THE SPARE TIRE IS MOUNTED) CAN OCCUR AND CAUSE THE SPARE TIRE TO SEPARATE FROM THE VEHICLE AND CAN ALSO LEAD TO REAR BRAKE FAILURE.TOYOTA STATED: TOYOTA HAS TENTATIVELY CONCLUDED THAT THE ROOT CAUSE IS A COMBINATION OF FACTORS, INCLUDING USAGE IN AREAS WHERE ROAD SALT IS APPLIED, INADEQUATE VEHICLE MAINTENANCE (I.E., NOT FOLLOWING THE RECOMMENDATIONS IN THE OWNER'S MANUAL), THE DESIGN OF THE REAR CROSS-MEMBER, AND MANUFACTURING ISSUES.THE DESIGN OF THE REAR CROSS-MEMBER IS SUCH THAT IT IS OPEN ON THE TOP SIDE AND SUSCEPTIBLE TO ACCUMULATION OF DIRT, WATER AND ROAD SALT.MANUFACTURING ISSUES OF THE REAR CROSS-MEMBER RELATED TO THE COATING PROCESS ALSO AFFECT ITS CORROSION RESISTANCE.TOYOTA ALSO STATES THAT OWNERS OF MY 2000 THROUGH 2003 VEHICLES IN STATES NOT COVERED BY THE RECALL WILL BE NOTIFIED ON HOW TO OBTAIN THE SAME INSPECTION AND REPAIR AS THE RECALLED VEHICLES, FREE OF CHARGE.FURTHER TOYOTA STATES: PLEASE NOTE THAT WHILE TOYOTA HAS NOT DETERMINED A DEFECT EXISTS IN 2004 THROUGH 2006 MY TUNDRA VEHICLES, TOYOTA PLANS ON INITIATING A FIELD ACTION IN THE NEAR FUTURE TO PREVENT FUTURE CORROSION ON THOSE VEHICLES ORIGINALLY SOLD OR CURRENTLY REGISTERED IN THE AFFECTED REGION AT NO COST TO THE OWNER.BY LETTER OF JANUARY 8, 2010 TOYOTA HAS NOTIFIED THE AGENCY THAT IT AMENDED ITS DEFECT INFORMATION REPORT FOR SAFETY RECALL 09V-444 TO INCLUDE THE FUEL TANK MOUNTING SYSTEM (I.E., FUEL TANK SUPPORT STRAPS AND FUEL TANK MOUNTING CROSS-MEMBERS) IN THE SAFETY RECALL.TOYOTA STATES: TOYOTA HAS NOT DECIDED THAT THE FUEL TANK MOUNTING SYSTEM IN THOSE VEHICLES CONTAINS A SAFETY-RELATED DEFECT WITHIN THE MEANING OF FEDERAL MOTOR VEHICLE SAFETY LAW.RATHER, TOYOTA IS TAKING THIS ACTION AT ODI'S REQUEST AND TO AVOID FUTURE DISAGREEMENT WITH ODI WITH RESPECT TO THIS ISSUE.MY 2007 AND NEWER TUNDRA VEHICLES ARE NOT INCLUDED IN ANY OF TOYOTA'S ACTIONS AS THE REAR CROSS-MEMBER IN THOSE VEHICLES HAVE BEEN REDESIGNED SO THAT IT IS OPEN ON THE BOTTOM.THE ACTIONS TAKEN BY TOYOTA ARE SUFFICIENT TO RESOLVE THE ISSUES RAISED BY THIS INVESTIGATION.ACCORDINGLY, THIS INVESTIGATION IS CLOSED.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT A SAFETY-RELATED DEFECT DOES NOT EXIST IN THE SUBJECT VEHICLES.THE AGENCY WILL TAKE FURTHER ACTION IF WARRANTED BY THE CIRCUMSTANCES.
Fuel System, Gasoline:storage:tank Assembly
THIS INVESTIGATION WAS OPENED BASED ON 20 REPORTS OF MODEL YEAR (MY) 2000 AND 2001 VEHICLES EXPERIENCING SEVERE CORROSION OF THE FRAME, RESULTING IN EITHER UNDER-BODY MOUNTED SPARE TIRE SEPARATION OR REAR BRAKE FAILURE.THE FAILURE REPORT COUNTS SHOWN ABOVE ARE FOR MY 2000 AND 2001 VEHICLES ONLY.BY LETTER OF NOVEMBER 16, 2009 TOYOTA HAS NOTIFIED THE AGENCY THAT IT WILL CONDUCT A SAFETY RECALL (09V-444) OF APPROXIMATELY 110,000 MODEL YEAR (MY) 2000 THROUGH 2003 TUNDRA VEHICLES.THE AFFECTED RECALLED VEHICLES WERE SOLD OR ARE CURRENTLY REGISTERED IN THE DISTRICT OF COLUMBIA AND THE STATES OF CT, DE, IL, IN, KY, MA, MD, ME, MI, MN, NH, NJ, NY, OH, PA, RI, VA, VT, WI, WV.TOYOTA ALLEGES HIGH AMOUNTS OF ROAD SALTS ARE USED IN THESE AREAS AND EXCESSIVE CORROSION OF THE REAR CROSS-MEMBER (TO WHICH THE SPARE TIRE IS MOUNTED) CAN OCCUR AND CAUSE THE SPARE TIRE TO SEPARATE FROM THE VEHICLE AND CAN ALSO LEAD TO REAR BRAKE FAILURE.TOYOTA STATED: TOYOTA HAS TENTATIVELY CONCLUDED THAT THE ROOT CAUSE IS A COMBINATION OF FACTORS, INCLUDING USAGE IN AREAS WHERE ROAD SALT IS APPLIED, INADEQUATE VEHICLE MAINTENANCE (I.E., NOT FOLLOWING THE RECOMMENDATIONS IN THE OWNER'S MANUAL), THE DESIGN OF THE REAR CROSS-MEMBER, AND MANUFACTURING ISSUES.THE DESIGN OF THE REAR CROSS-MEMBER IS SUCH THAT IT IS OPEN ON THE TOP SIDE AND SUSCEPTIBLE TO ACCUMULATION OF DIRT, WATER AND ROAD SALT.MANUFACTURING ISSUES OF THE REAR CROSS-MEMBER RELATED TO THE COATING PROCESS ALSO AFFECT ITS CORROSION RESISTANCE.TOYOTA ALSO STATES THAT OWNERS OF MY 2000 THROUGH 2003 VEHICLES IN STATES NOT COVERED BY THE RECALL WILL BE NOTIFIED ON HOW TO OBTAIN THE SAME INSPECTION AND REPAIR AS THE RECALLED VEHICLES, FREE OF CHARGE.FURTHER TOYOTA STATES: PLEASE NOTE THAT WHILE TOYOTA HAS NOT DETERMINED A DEFECT EXISTS IN 2004 THROUGH 2006 MY TUNDRA VEHICLES, TOYOTA PLANS ON INITIATING A FIELD ACTION IN THE NEAR FUTURE TO PREVENT FUTURE CORROSION ON THOSE VEHICLES ORIGINALLY SOLD OR CURRENTLY REGISTERED IN THE AFFECTED REGION AT NO COST TO THE OWNER.BY LETTER OF JANUARY 8, 2010 TOYOTA HAS NOTIFIED THE AGENCY THAT IT AMENDED ITS DEFECT INFORMATION REPORT FOR SAFETY RECALL 09V-444 TO INCLUDE THE FUEL TANK MOUNTING SYSTEM (I.E., FUEL TANK SUPPORT STRAPS AND FUEL TANK MOUNTING CROSS-MEMBERS) IN THE SAFETY RECALL.TOYOTA STATES: TOYOTA HAS NOT DECIDED THAT THE FUEL TANK MOUNTING SYSTEM IN THOSE VEHICLES CONTAINS A SAFETY-RELATED DEFECT WITHIN THE MEANING OF FEDERAL MOTOR VEHICLE SAFETY LAW.RATHER, TOYOTA IS TAKING THIS ACTION AT ODI'S REQUEST AND TO AVOID FUTURE DISAGREEMENT WITH ODI WITH RESPECT TO THIS ISSUE.MY 2007 AND NEWER TUNDRA VEHICLES ARE NOT INCLUDED IN ANY OF TOYOTA'S ACTIONS AS THE REAR CROSS-MEMBER IN THOSE VEHICLES HAVE BEEN REDESIGNED SO THAT IT IS OPEN ON THE BOTTOM.THE ACTIONS TAKEN BY TOYOTA ARE SUFFICIENT TO RESOLVE THE ISSUES RAISED BY THIS INVESTIGATION.ACCORDINGLY, THIS INVESTIGATION IS CLOSED.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT A SAFETY-RELATED DEFECT DOES NOT EXIST IN THE SUBJECT VEHICLES.THE AGENCY WILL TAKE FURTHER ACTION IF WARRANTED BY THE CIRCUMSTANCES.
Fuel System, Gasoline
THIS INVESTIGATION WAS OPENED BASED ON 20 REPORTS OF MODEL YEAR (MY) 2000 AND 2001 VEHICLES EXPERIENCING SEVERE CORROSION OF THE FRAME, RESULTING IN EITHER UNDER-BODY MOUNTED SPARE TIRE SEPARATION OR REAR BRAKE FAILURE.THE FAILURE REPORT COUNTS SHOWN ABOVE ARE FOR MY 2000 AND 2001 VEHICLES ONLY.BY LETTER OF NOVEMBER 16, 2009 TOYOTA HAS NOTIFIED THE AGENCY THAT IT WILL CONDUCT A SAFETY RECALL (09V-444) OF APPROXIMATELY 110,000 MODEL YEAR (MY) 2000 THROUGH 2003 TUNDRA VEHICLES.THE AFFECTED RECALLED VEHICLES WERE SOLD OR ARE CURRENTLY REGISTERED IN THE DISTRICT OF COLUMBIA AND THE STATES OF CT, DE, IL, IN, KY, MA, MD, ME, MI, MN, NH, NJ, NY, OH, PA, RI, VA, VT, WI, WV.TOYOTA ALLEGES HIGH AMOUNTS OF ROAD SALTS ARE USED IN THESE AREAS AND EXCESSIVE CORROSION OF THE REAR CROSS-MEMBER (TO WHICH THE SPARE TIRE IS MOUNTED) CAN OCCUR AND CAUSE THE SPARE TIRE TO SEPARATE FROM THE VEHICLE AND CAN ALSO LEAD TO REAR BRAKE FAILURE.TOYOTA STATED: TOYOTA HAS TENTATIVELY CONCLUDED THAT THE ROOT CAUSE IS A COMBINATION OF FACTORS, INCLUDING USAGE IN AREAS WHERE ROAD SALT IS APPLIED, INADEQUATE VEHICLE MAINTENANCE (I.E., NOT FOLLOWING THE RECOMMENDATIONS IN THE OWNER'S MANUAL), THE DESIGN OF THE REAR CROSS-MEMBER, AND MANUFACTURING ISSUES.THE DESIGN OF THE REAR CROSS-MEMBER IS SUCH THAT IT IS OPEN ON THE TOP SIDE AND SUSCEPTIBLE TO ACCUMULATION OF DIRT, WATER AND ROAD SALT.MANUFACTURING ISSUES OF THE REAR CROSS-MEMBER RELATED TO THE COATING PROCESS ALSO AFFECT ITS CORROSION RESISTANCE.TOYOTA ALSO STATES THAT OWNERS OF MY 2000 THROUGH 2003 VEHICLES IN STATES NOT COVERED BY THE RECALL WILL BE NOTIFIED ON HOW TO OBTAIN THE SAME INSPECTION AND REPAIR AS THE RECALLED VEHICLES, FREE OF CHARGE.FURTHER TOYOTA STATES: PLEASE NOTE THAT WHILE TOYOTA HAS NOT DETERMINED A DEFECT EXISTS IN 2004 THROUGH 2006 MY TUNDRA VEHICLES, TOYOTA PLANS ON INITIATING A FIELD ACTION IN THE NEAR FUTURE TO PREVENT FUTURE CORROSION ON THOSE VEHICLES ORIGINALLY SOLD OR CURRENTLY REGISTERED IN THE AFFECTED REGION AT NO COST TO THE OWNER.BY LETTER OF JANUARY 8, 2010 TOYOTA HAS NOTIFIED THE AGENCY THAT IT AMENDED ITS DEFECT INFORMATION REPORT FOR SAFETY RECALL 09V-444 TO INCLUDE THE FUEL TANK MOUNTING SYSTEM (I.E., FUEL TANK SUPPORT STRAPS AND FUEL TANK MOUNTING CROSS-MEMBERS) IN THE SAFETY RECALL.TOYOTA STATES: TOYOTA HAS NOT DECIDED THAT THE FUEL TANK MOUNTING SYSTEM IN THOSE VEHICLES CONTAINS A SAFETY-RELATED DEFECT WITHIN THE MEANING OF FEDERAL MOTOR VEHICLE SAFETY LAW.RATHER, TOYOTA IS TAKING THIS ACTION AT ODI'S REQUEST AND TO AVOID FUTURE DISAGREEMENT WITH ODI WITH RESPECT TO THIS ISSUE.MY 2007 AND NEWER TUNDRA VEHICLES ARE NOT INCLUDED IN ANY OF TOYOTA'S ACTIONS AS THE REAR CROSS-MEMBER IN THOSE VEHICLES HAVE BEEN REDESIGNED SO THAT IT IS OPEN ON THE BOTTOM.THE ACTIONS TAKEN BY TOYOTA ARE SUFFICIENT TO RESOLVE THE ISSUES RAISED BY THIS INVESTIGATION.ACCORDINGLY, THIS INVESTIGATION IS CLOSED.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT A SAFETY-RELATED DEFECT DOES NOT EXIST IN THE SUBJECT VEHICLES.THE AGENCY WILL TAKE FURTHER ACTION IF WARRANTED BY THE CIRCUMSTANCES.
Service Brakes, Hydraulic:foundation Components:differential Proportional Valve
THIS INVESTIGATION WAS OPENED BASED ON 20 REPORTS OF MODEL YEAR (MY) 2000 AND 2001 VEHICLES EXPERIENCING SEVERE CORROSION OF THE FRAME, RESULTING IN EITHER UNDER-BODY MOUNTED SPARE TIRE SEPARATION OR REAR BRAKE FAILURE.THE FAILURE REPORT COUNTS SHOWN ABOVE ARE FOR MY 2000 AND 2001 VEHICLES ONLY.BY LETTER OF NOVEMBER 16, 2009 TOYOTA HAS NOTIFIED THE AGENCY THAT IT WILL CONDUCT A SAFETY RECALL (09V-444) OF APPROXIMATELY 110,000 MODEL YEAR (MY) 2000 THROUGH 2003 TUNDRA VEHICLES.THE AFFECTED RECALLED VEHICLES WERE SOLD OR ARE CURRENTLY REGISTERED IN THE DISTRICT OF COLUMBIA AND THE STATES OF CT, DE, IL, IN, KY, MA, MD, ME, MI, MN, NH, NJ, NY, OH, PA, RI, VA, VT, WI, WV.TOYOTA ALLEGES HIGH AMOUNTS OF ROAD SALTS ARE USED IN THESE AREAS AND EXCESSIVE CORROSION OF THE REAR CROSS-MEMBER (TO WHICH THE SPARE TIRE IS MOUNTED) CAN OCCUR AND CAUSE THE SPARE TIRE TO SEPARATE FROM THE VEHICLE AND CAN ALSO LEAD TO REAR BRAKE FAILURE.TOYOTA STATED: TOYOTA HAS TENTATIVELY CONCLUDED THAT THE ROOT CAUSE IS A COMBINATION OF FACTORS, INCLUDING USAGE IN AREAS WHERE ROAD SALT IS APPLIED, INADEQUATE VEHICLE MAINTENANCE (I.E., NOT FOLLOWING THE RECOMMENDATIONS IN THE OWNER'S MANUAL), THE DESIGN OF THE REAR CROSS-MEMBER, AND MANUFACTURING ISSUES.THE DESIGN OF THE REAR CROSS-MEMBER IS SUCH THAT IT IS OPEN ON THE TOP SIDE AND SUSCEPTIBLE TO ACCUMULATION OF DIRT, WATER AND ROAD SALT.MANUFACTURING ISSUES OF THE REAR CROSS-MEMBER RELATED TO THE COATING PROCESS ALSO AFFECT ITS CORROSION RESISTANCE.TOYOTA ALSO STATES THAT OWNERS OF MY 2000 THROUGH 2003 VEHICLES IN STATES NOT COVERED BY THE RECALL WILL BE NOTIFIED ON HOW TO OBTAIN THE SAME INSPECTION AND REPAIR AS THE RECALLED VEHICLES, FREE OF CHARGE.FURTHER TOYOTA STATES: PLEASE NOTE THAT WHILE TOYOTA HAS NOT DETERMINED A DEFECT EXISTS IN 2004 THROUGH 2006 MY TUNDRA VEHICLES, TOYOTA PLANS ON INITIATING A FIELD ACTION IN THE NEAR FUTURE TO PREVENT FUTURE CORROSION ON THOSE VEHICLES ORIGINALLY SOLD OR CURRENTLY REGISTERED IN THE AFFECTED REGION AT NO COST TO THE OWNER.BY LETTER OF JANUARY 8, 2010 TOYOTA HAS NOTIFIED THE AGENCY THAT IT AMENDED ITS DEFECT INFORMATION REPORT FOR SAFETY RECALL 09V-444 TO INCLUDE THE FUEL TANK MOUNTING SYSTEM (I.E., FUEL TANK SUPPORT STRAPS AND FUEL TANK MOUNTING CROSS-MEMBERS) IN THE SAFETY RECALL.TOYOTA STATES: TOYOTA HAS NOT DECIDED THAT THE FUEL TANK MOUNTING SYSTEM IN THOSE VEHICLES CONTAINS A SAFETY-RELATED DEFECT WITHIN THE MEANING OF FEDERAL MOTOR VEHICLE SAFETY LAW.RATHER, TOYOTA IS TAKING THIS ACTION AT ODI'S REQUEST AND TO AVOID FUTURE DISAGREEMENT WITH ODI WITH RESPECT TO THIS ISSUE.MY 2007 AND NEWER TUNDRA VEHICLES ARE NOT INCLUDED IN ANY OF TOYOTA'S ACTIONS AS THE REAR CROSS-MEMBER IN THOSE VEHICLES HAVE BEEN REDESIGNED SO THAT IT IS OPEN ON THE BOTTOM.THE ACTIONS TAKEN BY TOYOTA ARE SUFFICIENT TO RESOLVE THE ISSUES RAISED BY THIS INVESTIGATION.ACCORDINGLY, THIS INVESTIGATION IS CLOSED.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT A SAFETY-RELATED DEFECT DOES NOT EXIST IN THE SUBJECT VEHICLES.THE AGENCY WILL TAKE FURTHER ACTION IF WARRANTED BY THE CIRCUMSTANCES.
Service Brakes, Hydraulic:foundation Components:hoses, Lines/piping, And Fittings
THIS INVESTIGATION WAS OPENED BASED ON 20 REPORTS OF MODEL YEAR (MY) 2000 AND 2001 VEHICLES EXPERIENCING SEVERE CORROSION OF THE FRAME, RESULTING IN EITHER UNDER-BODY MOUNTED SPARE TIRE SEPARATION OR REAR BRAKE FAILURE.THE FAILURE REPORT COUNTS SHOWN ABOVE ARE FOR MY 2000 AND 2001 VEHICLES ONLY.BY LETTER OF NOVEMBER 16, 2009 TOYOTA HAS NOTIFIED THE AGENCY THAT IT WILL CONDUCT A SAFETY RECALL (09V-444) OF APPROXIMATELY 110,000 MODEL YEAR (MY) 2000 THROUGH 2003 TUNDRA VEHICLES.THE AFFECTED RECALLED VEHICLES WERE SOLD OR ARE CURRENTLY REGISTERED IN THE DISTRICT OF COLUMBIA AND THE STATES OF CT, DE, IL, IN, KY, MA, MD, ME, MI, MN, NH, NJ, NY, OH, PA, RI, VA, VT, WI, WV.TOYOTA ALLEGES HIGH AMOUNTS OF ROAD SALTS ARE USED IN THESE AREAS AND EXCESSIVE CORROSION OF THE REAR CROSS-MEMBER (TO WHICH THE SPARE TIRE IS MOUNTED) CAN OCCUR AND CAUSE THE SPARE TIRE TO SEPARATE FROM THE VEHICLE AND CAN ALSO LEAD TO REAR BRAKE FAILURE.TOYOTA STATED: TOYOTA HAS TENTATIVELY CONCLUDED THAT THE ROOT CAUSE IS A COMBINATION OF FACTORS, INCLUDING USAGE IN AREAS WHERE ROAD SALT IS APPLIED, INADEQUATE VEHICLE MAINTENANCE (I.E., NOT FOLLOWING THE RECOMMENDATIONS IN THE OWNER'S MANUAL), THE DESIGN OF THE REAR CROSS-MEMBER, AND MANUFACTURING ISSUES.THE DESIGN OF THE REAR CROSS-MEMBER IS SUCH THAT IT IS OPEN ON THE TOP SIDE AND SUSCEPTIBLE TO ACCUMULATION OF DIRT, WATER AND ROAD SALT.MANUFACTURING ISSUES OF THE REAR CROSS-MEMBER RELATED TO THE COATING PROCESS ALSO AFFECT ITS CORROSION RESISTANCE.TOYOTA ALSO STATES THAT OWNERS OF MY 2000 THROUGH 2003 VEHICLES IN STATES NOT COVERED BY THE RECALL WILL BE NOTIFIED ON HOW TO OBTAIN THE SAME INSPECTION AND REPAIR AS THE RECALLED VEHICLES, FREE OF CHARGE.FURTHER TOYOTA STATES: PLEASE NOTE THAT WHILE TOYOTA HAS NOT DETERMINED A DEFECT EXISTS IN 2004 THROUGH 2006 MY TUNDRA VEHICLES, TOYOTA PLANS ON INITIATING A FIELD ACTION IN THE NEAR FUTURE TO PREVENT FUTURE CORROSION ON THOSE VEHICLES ORIGINALLY SOLD OR CURRENTLY REGISTERED IN THE AFFECTED REGION AT NO COST TO THE OWNER.BY LETTER OF JANUARY 8, 2010 TOYOTA HAS NOTIFIED THE AGENCY THAT IT AMENDED ITS DEFECT INFORMATION REPORT FOR SAFETY RECALL 09V-444 TO INCLUDE THE FUEL TANK MOUNTING SYSTEM (I.E., FUEL TANK SUPPORT STRAPS AND FUEL TANK MOUNTING CROSS-MEMBERS) IN THE SAFETY RECALL.TOYOTA STATES: TOYOTA HAS NOT DECIDED THAT THE FUEL TANK MOUNTING SYSTEM IN THOSE VEHICLES CONTAINS A SAFETY-RELATED DEFECT WITHIN THE MEANING OF FEDERAL MOTOR VEHICLE SAFETY LAW.RATHER, TOYOTA IS TAKING THIS ACTION AT ODI'S REQUEST AND TO AVOID FUTURE DISAGREEMENT WITH ODI WITH RESPECT TO THIS ISSUE.MY 2007 AND NEWER TUNDRA VEHICLES ARE NOT INCLUDED IN ANY OF TOYOTA'S ACTIONS AS THE REAR CROSS-MEMBER IN THOSE VEHICLES HAVE BEEN REDESIGNED SO THAT IT IS OPEN ON THE BOTTOM.THE ACTIONS TAKEN BY TOYOTA ARE SUFFICIENT TO RESOLVE THE ISSUES RAISED BY THIS INVESTIGATION.ACCORDINGLY, THIS INVESTIGATION IS CLOSED.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT A SAFETY-RELATED DEFECT DOES NOT EXIST IN THE SUBJECT VEHICLES.THE AGENCY WILL TAKE FURTHER ACTION IF WARRANTED BY THE CIRCUMSTANCES.
Service Brakes, Hydraulic
THIS INVESTIGATION WAS OPENED BASED ON 20 REPORTS OF MODEL YEAR (MY) 2000 AND 2001 VEHICLES EXPERIENCING SEVERE CORROSION OF THE FRAME, RESULTING IN EITHER UNDER-BODY MOUNTED SPARE TIRE SEPARATION OR REAR BRAKE FAILURE.THE FAILURE REPORT COUNTS SHOWN ABOVE ARE FOR MY 2000 AND 2001 VEHICLES ONLY.BY LETTER OF NOVEMBER 16, 2009 TOYOTA HAS NOTIFIED THE AGENCY THAT IT WILL CONDUCT A SAFETY RECALL (09V-444) OF APPROXIMATELY 110,000 MODEL YEAR (MY) 2000 THROUGH 2003 TUNDRA VEHICLES.THE AFFECTED RECALLED VEHICLES WERE SOLD OR ARE CURRENTLY REGISTERED IN THE DISTRICT OF COLUMBIA AND THE STATES OF CT, DE, IL, IN, KY, MA, MD, ME, MI, MN, NH, NJ, NY, OH, PA, RI, VA, VT, WI, WV.TOYOTA ALLEGES HIGH AMOUNTS OF ROAD SALTS ARE USED IN THESE AREAS AND EXCESSIVE CORROSION OF THE REAR CROSS-MEMBER (TO WHICH THE SPARE TIRE IS MOUNTED) CAN OCCUR AND CAUSE THE SPARE TIRE TO SEPARATE FROM THE VEHICLE AND CAN ALSO LEAD TO REAR BRAKE FAILURE.TOYOTA STATED: TOYOTA HAS TENTATIVELY CONCLUDED THAT THE ROOT CAUSE IS A COMBINATION OF FACTORS, INCLUDING USAGE IN AREAS WHERE ROAD SALT IS APPLIED, INADEQUATE VEHICLE MAINTENANCE (I.E., NOT FOLLOWING THE RECOMMENDATIONS IN THE OWNER'S MANUAL), THE DESIGN OF THE REAR CROSS-MEMBER, AND MANUFACTURING ISSUES.THE DESIGN OF THE REAR CROSS-MEMBER IS SUCH THAT IT IS OPEN ON THE TOP SIDE AND SUSCEPTIBLE TO ACCUMULATION OF DIRT, WATER AND ROAD SALT.MANUFACTURING ISSUES OF THE REAR CROSS-MEMBER RELATED TO THE COATING PROCESS ALSO AFFECT ITS CORROSION RESISTANCE.TOYOTA ALSO STATES THAT OWNERS OF MY 2000 THROUGH 2003 VEHICLES IN STATES NOT COVERED BY THE RECALL WILL BE NOTIFIED ON HOW TO OBTAIN THE SAME INSPECTION AND REPAIR AS THE RECALLED VEHICLES, FREE OF CHARGE.FURTHER TOYOTA STATES: PLEASE NOTE THAT WHILE TOYOTA HAS NOT DETERMINED A DEFECT EXISTS IN 2004 THROUGH 2006 MY TUNDRA VEHICLES, TOYOTA PLANS ON INITIATING A FIELD ACTION IN THE NEAR FUTURE TO PREVENT FUTURE CORROSION ON THOSE VEHICLES ORIGINALLY SOLD OR CURRENTLY REGISTERED IN THE AFFECTED REGION AT NO COST TO THE OWNER.BY LETTER OF JANUARY 8, 2010 TOYOTA HAS NOTIFIED THE AGENCY THAT IT AMENDED ITS DEFECT INFORMATION REPORT FOR SAFETY RECALL 09V-444 TO INCLUDE THE FUEL TANK MOUNTING SYSTEM (I.E., FUEL TANK SUPPORT STRAPS AND FUEL TANK MOUNTING CROSS-MEMBERS) IN THE SAFETY RECALL.TOYOTA STATES: TOYOTA HAS NOT DECIDED THAT THE FUEL TANK MOUNTING SYSTEM IN THOSE VEHICLES CONTAINS A SAFETY-RELATED DEFECT WITHIN THE MEANING OF FEDERAL MOTOR VEHICLE SAFETY LAW.RATHER, TOYOTA IS TAKING THIS ACTION AT ODI'S REQUEST AND TO AVOID FUTURE DISAGREEMENT WITH ODI WITH RESPECT TO THIS ISSUE.MY 2007 AND NEWER TUNDRA VEHICLES ARE NOT INCLUDED IN ANY OF TOYOTA'S ACTIONS AS THE REAR CROSS-MEMBER IN THOSE VEHICLES HAVE BEEN REDESIGNED SO THAT IT IS OPEN ON THE BOTTOM.THE ACTIONS TAKEN BY TOYOTA ARE SUFFICIENT TO RESOLVE THE ISSUES RAISED BY THIS INVESTIGATION.ACCORDINGLY, THIS INVESTIGATION IS CLOSED.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT A SAFETY-RELATED DEFECT DOES NOT EXIST IN THE SUBJECT VEHICLES.THE AGENCY WILL TAKE FURTHER ACTION IF WARRANTED BY THE CIRCUMSTANCES.
Structure:frame And Members
THIS INVESTIGATION WAS OPENED BASED ON 20 REPORTS OF MODEL YEAR (MY) 2000 AND 2001 VEHICLES EXPERIENCING SEVERE CORROSION OF THE FRAME, RESULTING IN EITHER UNDER-BODY MOUNTED SPARE TIRE SEPARATION OR REAR BRAKE FAILURE.THE FAILURE REPORT COUNTS SHOWN ABOVE ARE FOR MY 2000 AND 2001 VEHICLES ONLY.BY LETTER OF NOVEMBER 16, 2009 TOYOTA HAS NOTIFIED THE AGENCY THAT IT WILL CONDUCT A SAFETY RECALL (09V-444) OF APPROXIMATELY 110,000 MODEL YEAR (MY) 2000 THROUGH 2003 TUNDRA VEHICLES.THE AFFECTED RECALLED VEHICLES WERE SOLD OR ARE CURRENTLY REGISTERED IN THE DISTRICT OF COLUMBIA AND THE STATES OF CT, DE, IL, IN, KY, MA, MD, ME, MI, MN, NH, NJ, NY, OH, PA, RI, VA, VT, WI, WV.TOYOTA ALLEGES HIGH AMOUNTS OF ROAD SALTS ARE USED IN THESE AREAS AND EXCESSIVE CORROSION OF THE REAR CROSS-MEMBER (TO WHICH THE SPARE TIRE IS MOUNTED) CAN OCCUR AND CAUSE THE SPARE TIRE TO SEPARATE FROM THE VEHICLE AND CAN ALSO LEAD TO REAR BRAKE FAILURE.TOYOTA STATED: TOYOTA HAS TENTATIVELY CONCLUDED THAT THE ROOT CAUSE IS A COMBINATION OF FACTORS, INCLUDING USAGE IN AREAS WHERE ROAD SALT IS APPLIED, INADEQUATE VEHICLE MAINTENANCE (I.E., NOT FOLLOWING THE RECOMMENDATIONS IN THE OWNER'S MANUAL), THE DESIGN OF THE REAR CROSS-MEMBER, AND MANUFACTURING ISSUES.THE DESIGN OF THE REAR CROSS-MEMBER IS SUCH THAT IT IS OPEN ON THE TOP SIDE AND SUSCEPTIBLE TO ACCUMULATION OF DIRT, WATER AND ROAD SALT.MANUFACTURING ISSUES OF THE REAR CROSS-MEMBER RELATED TO THE COATING PROCESS ALSO AFFECT ITS CORROSION RESISTANCE.TOYOTA ALSO STATES THAT OWNERS OF MY 2000 THROUGH 2003 VEHICLES IN STATES NOT COVERED BY THE RECALL WILL BE NOTIFIED ON HOW TO OBTAIN THE SAME INSPECTION AND REPAIR AS THE RECALLED VEHICLES, FREE OF CHARGE.FURTHER TOYOTA STATES: PLEASE NOTE THAT WHILE TOYOTA HAS NOT DETERMINED A DEFECT EXISTS IN 2004 THROUGH 2006 MY TUNDRA VEHICLES, TOYOTA PLANS ON INITIATING A FIELD ACTION IN THE NEAR FUTURE TO PREVENT FUTURE CORROSION ON THOSE VEHICLES ORIGINALLY SOLD OR CURRENTLY REGISTERED IN THE AFFECTED REGION AT NO COST TO THE OWNER.BY LETTER OF JANUARY 8, 2010 TOYOTA HAS NOTIFIED THE AGENCY THAT IT AMENDED ITS DEFECT INFORMATION REPORT FOR SAFETY RECALL 09V-444 TO INCLUDE THE FUEL TANK MOUNTING SYSTEM (I.E., FUEL TANK SUPPORT STRAPS AND FUEL TANK MOUNTING CROSS-MEMBERS) IN THE SAFETY RECALL.TOYOTA STATES: TOYOTA HAS NOT DECIDED THAT THE FUEL TANK MOUNTING SYSTEM IN THOSE VEHICLES CONTAINS A SAFETY-RELATED DEFECT WITHIN THE MEANING OF FEDERAL MOTOR VEHICLE SAFETY LAW.RATHER, TOYOTA IS TAKING THIS ACTION AT ODI'S REQUEST AND TO AVOID FUTURE DISAGREEMENT WITH ODI WITH RESPECT TO THIS ISSUE.MY 2007 AND NEWER TUNDRA VEHICLES ARE NOT INCLUDED IN ANY OF TOYOTA'S ACTIONS AS THE REAR CROSS-MEMBER IN THOSE VEHICLES HAVE BEEN REDESIGNED SO THAT IT IS OPEN ON THE BOTTOM.THE ACTIONS TAKEN BY TOYOTA ARE SUFFICIENT TO RESOLVE THE ISSUES RAISED BY THIS INVESTIGATION.ACCORDINGLY, THIS INVESTIGATION IS CLOSED.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT A SAFETY-RELATED DEFECT DOES NOT EXIST IN THE SUBJECT VEHICLES.THE AGENCY WILL TAKE FURTHER ACTION IF WARRANTED BY THE CIRCUMSTANCES.
Tires:temporary/emergency Spare Tire
THIS INVESTIGATION WAS OPENED BASED ON 20 REPORTS OF MODEL YEAR (MY) 2000 AND 2001 VEHICLES EXPERIENCING SEVERE CORROSION OF THE FRAME, RESULTING IN EITHER UNDER-BODY MOUNTED SPARE TIRE SEPARATION OR REAR BRAKE FAILURE.THE FAILURE REPORT COUNTS SHOWN ABOVE ARE FOR MY 2000 AND 2001 VEHICLES ONLY.BY LETTER OF NOVEMBER 16, 2009 TOYOTA HAS NOTIFIED THE AGENCY THAT IT WILL CONDUCT A SAFETY RECALL (09V-444) OF APPROXIMATELY 110,000 MODEL YEAR (MY) 2000 THROUGH 2003 TUNDRA VEHICLES.THE AFFECTED RECALLED VEHICLES WERE SOLD OR ARE CURRENTLY REGISTERED IN THE DISTRICT OF COLUMBIA AND THE STATES OF CT, DE, IL, IN, KY, MA, MD, ME, MI, MN, NH, NJ, NY, OH, PA, RI, VA, VT, WI, WV.TOYOTA ALLEGES HIGH AMOUNTS OF ROAD SALTS ARE USED IN THESE AREAS AND EXCESSIVE CORROSION OF THE REAR CROSS-MEMBER (TO WHICH THE SPARE TIRE IS MOUNTED) CAN OCCUR AND CAUSE THE SPARE TIRE TO SEPARATE FROM THE VEHICLE AND CAN ALSO LEAD TO REAR BRAKE FAILURE.TOYOTA STATED: TOYOTA HAS TENTATIVELY CONCLUDED THAT THE ROOT CAUSE IS A COMBINATION OF FACTORS, INCLUDING USAGE IN AREAS WHERE ROAD SALT IS APPLIED, INADEQUATE VEHICLE MAINTENANCE (I.E., NOT FOLLOWING THE RECOMMENDATIONS IN THE OWNER'S MANUAL), THE DESIGN OF THE REAR CROSS-MEMBER, AND MANUFACTURING ISSUES.THE DESIGN OF THE REAR CROSS-MEMBER IS SUCH THAT IT IS OPEN ON THE TOP SIDE AND SUSCEPTIBLE TO ACCUMULATION OF DIRT, WATER AND ROAD SALT.MANUFACTURING ISSUES OF THE REAR CROSS-MEMBER RELATED TO THE COATING PROCESS ALSO AFFECT ITS CORROSION RESISTANCE.TOYOTA ALSO STATES THAT OWNERS OF MY 2000 THROUGH 2003 VEHICLES IN STATES NOT COVERED BY THE RECALL WILL BE NOTIFIED ON HOW TO OBTAIN THE SAME INSPECTION AND REPAIR AS THE RECALLED VEHICLES, FREE OF CHARGE.FURTHER TOYOTA STATES: PLEASE NOTE THAT WHILE TOYOTA HAS NOT DETERMINED A DEFECT EXISTS IN 2004 THROUGH 2006 MY TUNDRA VEHICLES, TOYOTA PLANS ON INITIATING A FIELD ACTION IN THE NEAR FUTURE TO PREVENT FUTURE CORROSION ON THOSE VEHICLES ORIGINALLY SOLD OR CURRENTLY REGISTERED IN THE AFFECTED REGION AT NO COST TO THE OWNER.BY LETTER OF JANUARY 8, 2010 TOYOTA HAS NOTIFIED THE AGENCY THAT IT AMENDED ITS DEFECT INFORMATION REPORT FOR SAFETY RECALL 09V-444 TO INCLUDE THE FUEL TANK MOUNTING SYSTEM (I.E., FUEL TANK SUPPORT STRAPS AND FUEL TANK MOUNTING CROSS-MEMBERS) IN THE SAFETY RECALL.TOYOTA STATES: TOYOTA HAS NOT DECIDED THAT THE FUEL TANK MOUNTING SYSTEM IN THOSE VEHICLES CONTAINS A SAFETY-RELATED DEFECT WITHIN THE MEANING OF FEDERAL MOTOR VEHICLE SAFETY LAW.RATHER, TOYOTA IS TAKING THIS ACTION AT ODI'S REQUEST AND TO AVOID FUTURE DISAGREEMENT WITH ODI WITH RESPECT TO THIS ISSUE.MY 2007 AND NEWER TUNDRA VEHICLES ARE NOT INCLUDED IN ANY OF TOYOTA'S ACTIONS AS THE REAR CROSS-MEMBER IN THOSE VEHICLES HAVE BEEN REDESIGNED SO THAT IT IS OPEN ON THE BOTTOM.THE ACTIONS TAKEN BY TOYOTA ARE SUFFICIENT TO RESOLVE THE ISSUES RAISED BY THIS INVESTIGATION.ACCORDINGLY, THIS INVESTIGATION IS CLOSED.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT A SAFETY-RELATED DEFECT DOES NOT EXIST IN THE SUBJECT VEHICLES.THE AGENCY WILL TAKE FURTHER ACTION IF WARRANTED BY THE CIRCUMSTANCES.
EA04024 · Ball Joint Separation
Opened Aug 20, 2004 · Closed Jul 8, 2005
Status: closed (inferred from source dates) · Suspension; Suspension:front:control Arm; Suspension:front:control Arm:lower Arm; Suspension:front:control Arm:lower Ball Joint
ODI RECEIVED 3 CONSUMER REPORTS OF ALLEGED BALL JOINT SEPARATION ON MY 2002 TUNDRA VEHICLES.THE COMPLAINTS ALLEGE THAT A FRONT SUSPENSION BALL JOINT SEPARATED WHILE DRIVING, WHICH CAUSED THE SUSPENSION TO COLLAPSE AND RESULTED IN A LOSS OF VEHICLE CONTROL.BASED ON THESE COMPLAINTS, ODI OPENED PE02-040 AND LATER UPGRADED TO EA04-024 FOR MY 2002 TUNDRA VEHICLES.DURING EA04-024, ADDITIONAL FAILURE DATA WAS IDENTIFIED AS NOTED IN THE FAILURE REPORT SUMMARY ABOVE. ON MAY 16, 2005, TOYOTA NOTIFIED NHTSA OF A SAFETY DEFECT ON MY 2002-2004 TUNDRA AND SEQUOIA VEHICLES (PRODUCED BETWEEN AUGUST 1, 2001 AND SEPTEMBER 30, 2003), MY 2001-2004 TACOMA VEHICLES (PRODUCED BETWEEN JULY 31, 2001 AND DECEMBER 23, 2003), AND MY 2001-2002 4RUNNER VEHICLES (PRODUCED BETWEEN MAY 22, 2001 AND AUGUST 23, 2002).THE NOTIFICATION STATED THAT DUE TO A MANUFACTURING ISSUE WITH THE FRONT SUSPENSION LOWER BALL JOINTS (WHICH CONNECT THE LOWER CONTROL ARMS TO THE STEERING KNUCKLES OF THE FRONT WHEELS) THERE IS A POSSIBILITY THAT THE SURFACE OF THE BALL OF THE JOINT MAY HAVE BEEN SCRATCHED.SUCH SCRATCHES MAY RESULT IN SIGNIFICANTLY ACCELERATED WEAR OF THE JOINT. ACCORDING TO TOYOTA, IF THE [SUBJECT] VEHICLE IS OPERATED FOR AN EXTENDED PERIOD OF TIME IN THIS CONDITION, THE BALL JOINT MAY EVENTUALLY EXPERIENCE EXCESSIVE WEAR AND LOOSENESS, RESULTING IN INCREASED STEERING EFFORT, REDUCED VEHICLE SELF-CENTERING, AND NOISE IN THE FRONT SUSPENSION.IN EXTREME CASES, WHEN THE DRIVER CONTINUES TO OPERATE THE VEHICLE IN THIS CONDITION, THE LOWER BALL JOINT MAY SEPARATE FROM THE KNUCKLE CAUSING A LOSS OF VEHICLE STEERING CONTROL. TOYOTA WILL INSTRUCT OWNERS TO RETURN THEIR VEHICLES TO ANY TOYOTA DEALER FOR REPLACEMENT OF THE FRONT SUSPENSION LOWER BALL JOINTS.ODI WILL MONITOR THE EFFECTIVENESS OF THE REMEDY AND TAKE FURTHER ACTION IF WARRANTED.
Additional source detail variants (4)
Suspension:front:control Arm:lower Arm
ODI RECEIVED 3 CONSUMER REPORTS OF ALLEGED BALL JOINT SEPARATION ON MY 2002 TUNDRA VEHICLES.THE COMPLAINTS ALLEGE THAT A FRONT SUSPENSION BALL JOINT SEPARATED WHILE DRIVING, WHICH CAUSED THE SUSPENSION TO COLLAPSE AND RESULTED IN A LOSS OF VEHICLE CONTROL.BASED ON THESE COMPLAINTS, ODI OPENED PE02-040 AND LATER UPGRADED TO EA04-024 FOR MY 2002 TUNDRA VEHICLES.DURING EA04-024, ADDITIONAL FAILURE DATA WAS IDENTIFIED AS NOTED IN THE FAILURE REPORT SUMMARY ABOVE. ON MAY 16, 2005, TOYOTA NOTIFIED NHTSA OF A SAFETY DEFECT ON MY 2002-2004 TUNDRA AND SEQUOIA VEHICLES (PRODUCED BETWEEN AUGUST 1, 2001 AND SEPTEMBER 30, 2003), MY 2001-2004 TACOMA VEHICLES (PRODUCED BETWEEN JULY 31, 2001 AND DECEMBER 23, 2003), AND MY 2001-2002 4RUNNER VEHICLES (PRODUCED BETWEEN MAY 22, 2001 AND AUGUST 23, 2002).THE NOTIFICATION STATED THAT DUE TO A MANUFACTURING ISSUE WITH THE FRONT SUSPENSION LOWER BALL JOINTS (WHICH CONNECT THE LOWER CONTROL ARMS TO THE STEERING KNUCKLES OF THE FRONT WHEELS) THERE IS A POSSIBILITY THAT THE SURFACE OF THE BALL OF THE JOINT MAY HAVE BEEN SCRATCHED.SUCH SCRATCHES MAY RESULT IN SIGNIFICANTLY ACCELERATED WEAR OF THE JOINT. ACCORDING TO TOYOTA, IF THE [SUBJECT] VEHICLE IS OPERATED FOR AN EXTENDED PERIOD OF TIME IN THIS CONDITION, THE BALL JOINT MAY EVENTUALLY EXPERIENCE EXCESSIVE WEAR AND LOOSENESS, RESULTING IN INCREASED STEERING EFFORT, REDUCED VEHICLE SELF-CENTERING, AND NOISE IN THE FRONT SUSPENSION.IN EXTREME CASES, WHEN THE DRIVER CONTINUES TO OPERATE THE VEHICLE IN THIS CONDITION, THE LOWER BALL JOINT MAY SEPARATE FROM THE KNUCKLE CAUSING A LOSS OF VEHICLE STEERING CONTROL. TOYOTA WILL INSTRUCT OWNERS TO RETURN THEIR VEHICLES TO ANY TOYOTA DEALER FOR REPLACEMENT OF THE FRONT SUSPENSION LOWER BALL JOINTS.ODI WILL MONITOR THE EFFECTIVENESS OF THE REMEDY AND TAKE FURTHER ACTION IF WARRANTED.
Suspension:front:control Arm:lower Ball Joint
ODI RECEIVED 3 CONSUMER REPORTS OF ALLEGED BALL JOINT SEPARATION ON MY 2002 TUNDRA VEHICLES.THE COMPLAINTS ALLEGE THAT A FRONT SUSPENSION BALL JOINT SEPARATED WHILE DRIVING, WHICH CAUSED THE SUSPENSION TO COLLAPSE AND RESULTED IN A LOSS OF VEHICLE CONTROL.BASED ON THESE COMPLAINTS, ODI OPENED PE02-040 AND LATER UPGRADED TO EA04-024 FOR MY 2002 TUNDRA VEHICLES.DURING EA04-024, ADDITIONAL FAILURE DATA WAS IDENTIFIED AS NOTED IN THE FAILURE REPORT SUMMARY ABOVE. ON MAY 16, 2005, TOYOTA NOTIFIED NHTSA OF A SAFETY DEFECT ON MY 2002-2004 TUNDRA AND SEQUOIA VEHICLES (PRODUCED BETWEEN AUGUST 1, 2001 AND SEPTEMBER 30, 2003), MY 2001-2004 TACOMA VEHICLES (PRODUCED BETWEEN JULY 31, 2001 AND DECEMBER 23, 2003), AND MY 2001-2002 4RUNNER VEHICLES (PRODUCED BETWEEN MAY 22, 2001 AND AUGUST 23, 2002).THE NOTIFICATION STATED THAT DUE TO A MANUFACTURING ISSUE WITH THE FRONT SUSPENSION LOWER BALL JOINTS (WHICH CONNECT THE LOWER CONTROL ARMS TO THE STEERING KNUCKLES OF THE FRONT WHEELS) THERE IS A POSSIBILITY THAT THE SURFACE OF THE BALL OF THE JOINT MAY HAVE BEEN SCRATCHED.SUCH SCRATCHES MAY RESULT IN SIGNIFICANTLY ACCELERATED WEAR OF THE JOINT. ACCORDING TO TOYOTA, IF THE [SUBJECT] VEHICLE IS OPERATED FOR AN EXTENDED PERIOD OF TIME IN THIS CONDITION, THE BALL JOINT MAY EVENTUALLY EXPERIENCE EXCESSIVE WEAR AND LOOSENESS, RESULTING IN INCREASED STEERING EFFORT, REDUCED VEHICLE SELF-CENTERING, AND NOISE IN THE FRONT SUSPENSION.IN EXTREME CASES, WHEN THE DRIVER CONTINUES TO OPERATE THE VEHICLE IN THIS CONDITION, THE LOWER BALL JOINT MAY SEPARATE FROM THE KNUCKLE CAUSING A LOSS OF VEHICLE STEERING CONTROL. TOYOTA WILL INSTRUCT OWNERS TO RETURN THEIR VEHICLES TO ANY TOYOTA DEALER FOR REPLACEMENT OF THE FRONT SUSPENSION LOWER BALL JOINTS.ODI WILL MONITOR THE EFFECTIVENESS OF THE REMEDY AND TAKE FURTHER ACTION IF WARRANTED.
Suspension:front:control Arm
ODI RECEIVED 3 CONSUMER REPORTS OF ALLEGED BALL JOINT SEPARATION ON MY 2002 TUNDRA VEHICLES.THE COMPLAINTS ALLEGE THAT A FRONT SUSPENSION BALL JOINT SEPARATED WHILE DRIVING, WHICH CAUSED THE SUSPENSION TO COLLAPSE AND RESULTED IN A LOSS OF VEHICLE CONTROL.BASED ON THESE COMPLAINTS, ODI OPENED PE02-040 AND LATER UPGRADED TO EA04-024 FOR MY 2002 TUNDRA VEHICLES.DURING EA04-024, ADDITIONAL FAILURE DATA WAS IDENTIFIED AS NOTED IN THE FAILURE REPORT SUMMARY ABOVE. ON MAY 16, 2005, TOYOTA NOTIFIED NHTSA OF A SAFETY DEFECT ON MY 2002-2004 TUNDRA AND SEQUOIA VEHICLES (PRODUCED BETWEEN AUGUST 1, 2001 AND SEPTEMBER 30, 2003), MY 2001-2004 TACOMA VEHICLES (PRODUCED BETWEEN JULY 31, 2001 AND DECEMBER 23, 2003), AND MY 2001-2002 4RUNNER VEHICLES (PRODUCED BETWEEN MAY 22, 2001 AND AUGUST 23, 2002).THE NOTIFICATION STATED THAT DUE TO A MANUFACTURING ISSUE WITH THE FRONT SUSPENSION LOWER BALL JOINTS (WHICH CONNECT THE LOWER CONTROL ARMS TO THE STEERING KNUCKLES OF THE FRONT WHEELS) THERE IS A POSSIBILITY THAT THE SURFACE OF THE BALL OF THE JOINT MAY HAVE BEEN SCRATCHED.SUCH SCRATCHES MAY RESULT IN SIGNIFICANTLY ACCELERATED WEAR OF THE JOINT. ACCORDING TO TOYOTA, IF THE [SUBJECT] VEHICLE IS OPERATED FOR AN EXTENDED PERIOD OF TIME IN THIS CONDITION, THE BALL JOINT MAY EVENTUALLY EXPERIENCE EXCESSIVE WEAR AND LOOSENESS, RESULTING IN INCREASED STEERING EFFORT, REDUCED VEHICLE SELF-CENTERING, AND NOISE IN THE FRONT SUSPENSION.IN EXTREME CASES, WHEN THE DRIVER CONTINUES TO OPERATE THE VEHICLE IN THIS CONDITION, THE LOWER BALL JOINT MAY SEPARATE FROM THE KNUCKLE CAUSING A LOSS OF VEHICLE STEERING CONTROL. TOYOTA WILL INSTRUCT OWNERS TO RETURN THEIR VEHICLES TO ANY TOYOTA DEALER FOR REPLACEMENT OF THE FRONT SUSPENSION LOWER BALL JOINTS.ODI WILL MONITOR THE EFFECTIVENESS OF THE REMEDY AND TAKE FURTHER ACTION IF WARRANTED.
Suspension
ODI RECEIVED 3 CONSUMER REPORTS OF ALLEGED BALL JOINT SEPARATION ON MY 2002 TUNDRA VEHICLES.THE COMPLAINTS ALLEGE THAT A FRONT SUSPENSION BALL JOINT SEPARATED WHILE DRIVING, WHICH CAUSED THE SUSPENSION TO COLLAPSE AND RESULTED IN A LOSS OF VEHICLE CONTROL.BASED ON THESE COMPLAINTS, ODI OPENED PE02-040 AND LATER UPGRADED TO EA04-024 FOR MY 2002 TUNDRA VEHICLES.DURING EA04-024, ADDITIONAL FAILURE DATA WAS IDENTIFIED AS NOTED IN THE FAILURE REPORT SUMMARY ABOVE. ON MAY 16, 2005, TOYOTA NOTIFIED NHTSA OF A SAFETY DEFECT ON MY 2002-2004 TUNDRA AND SEQUOIA VEHICLES (PRODUCED BETWEEN AUGUST 1, 2001 AND SEPTEMBER 30, 2003), MY 2001-2004 TACOMA VEHICLES (PRODUCED BETWEEN JULY 31, 2001 AND DECEMBER 23, 2003), AND MY 2001-2002 4RUNNER VEHICLES (PRODUCED BETWEEN MAY 22, 2001 AND AUGUST 23, 2002).THE NOTIFICATION STATED THAT DUE TO A MANUFACTURING ISSUE WITH THE FRONT SUSPENSION LOWER BALL JOINTS (WHICH CONNECT THE LOWER CONTROL ARMS TO THE STEERING KNUCKLES OF THE FRONT WHEELS) THERE IS A POSSIBILITY THAT THE SURFACE OF THE BALL OF THE JOINT MAY HAVE BEEN SCRATCHED.SUCH SCRATCHES MAY RESULT IN SIGNIFICANTLY ACCELERATED WEAR OF THE JOINT. ACCORDING TO TOYOTA, IF THE [SUBJECT] VEHICLE IS OPERATED FOR AN EXTENDED PERIOD OF TIME IN THIS CONDITION, THE BALL JOINT MAY EVENTUALLY EXPERIENCE EXCESSIVE WEAR AND LOOSENESS, RESULTING IN INCREASED STEERING EFFORT, REDUCED VEHICLE SELF-CENTERING, AND NOISE IN THE FRONT SUSPENSION.IN EXTREME CASES, WHEN THE DRIVER CONTINUES TO OPERATE THE VEHICLE IN THIS CONDITION, THE LOWER BALL JOINT MAY SEPARATE FROM THE KNUCKLE CAUSING A LOSS OF VEHICLE STEERING CONTROL. TOYOTA WILL INSTRUCT OWNERS TO RETURN THEIR VEHICLES TO ANY TOYOTA DEALER FOR REPLACEMENT OF THE FRONT SUSPENSION LOWER BALL JOINTS.ODI WILL MONITOR THE EFFECTIVENESS OF THE REMEDY AND TAKE FURTHER ACTION IF WARRANTED.
PE04040 · Front Suspension Ball Joint Breakage
Opened Apr 13, 2004 · Closed Aug 20, 2004
Status: closed (inferred from source dates) · Suspension:front:control Arm:lower Ball Joint; Suspension:front:control Arm:upper Ball Joint
ODI OPENED PE04-040 BASED ON THREE CONSUMER REPORTS OF ALLEGED BALL JOINT FAILURE.THE COMPLAINTS ALLEGE THAT A FRONT SUSPENSION BALL JOINT SEPARATED WHILE DRIVING, WHICH CAUSED THE SUSPENSION TO COLLAPSE AND RESULTED IN A LOSS OF VEHICLE CONTROL.ALL OF THESE COMPLAINTS INVOLVED THE FAILURE OF A LOWER BALL JOINT.DURING THE INVESTIGATION, TOYOTA IDENTIFIED A TOTAL OF 15 COMPLAINTS OF LOWER BALL JOINT SEPARATION, ONE OF WHICH RESULTED IN A CRASH, AND 28 WARRANTY CLAIMS RELATED TO LOWER BALL JOINT WEAR.ODI'S ANALYSIS SHOWED THAT OF THE 15 SEPARATIONS, 11 WERE ON FOUR-WHEEL DRIVE VEHICLES (24.2 PER 100,000 VEHICLES), WHICH MAKE UP APPROXIMATELY 40% OF THE 2002 MY POPULATION (45,448 VEHICLES).ODI'S ANALYSIS ALSO SHOWED THAT SOME DRIVERS LOST FRONT BRAKING ABILITY AS THE BRAKE LINE SEVERED WHEN THE FRONT SUSPENSION COLLAPSED.THIS PRELIMINARY EVALUATION HAS BEEN UPGRADED TO AN ENGINEERING ANALYSIS TO FURTHER INVESTIGATE THIS ISSUE, TO ASSESS THE SAFETY-RELATED CONSEQUENCES, AND TO DETERMINE THE SCOPE OF THE AFFECTED POPULATION.
Additional source detail variants (2)
Suspension:front:control Arm:lower Ball Joint
ODI OPENED PE04-040 BASED ON THREE CONSUMER REPORTS OF ALLEGED BALL JOINT FAILURE.THE COMPLAINTS ALLEGE THAT A FRONT SUSPENSION BALL JOINT SEPARATED WHILE DRIVING, WHICH CAUSED THE SUSPENSION TO COLLAPSE AND RESULTED IN A LOSS OF VEHICLE CONTROL.ALL OF THESE COMPLAINTS INVOLVED THE FAILURE OF A LOWER BALL JOINT.DURING THE INVESTIGATION, TOYOTA IDENTIFIED A TOTAL OF 15 COMPLAINTS OF LOWER BALL JOINT SEPARATION, ONE OF WHICH RESULTED IN A CRASH, AND 28 WARRANTY CLAIMS RELATED TO LOWER BALL JOINT WEAR.ODI'S ANALYSIS SHOWED THAT OF THE 15 SEPARATIONS, 11 WERE ON FOUR-WHEEL DRIVE VEHICLES (24.2 PER 100,000 VEHICLES), WHICH MAKE UP APPROXIMATELY 40% OF THE 2002 MY POPULATION (45,448 VEHICLES).ODI'S ANALYSIS ALSO SHOWED THAT SOME DRIVERS LOST FRONT BRAKING ABILITY AS THE BRAKE LINE SEVERED WHEN THE FRONT SUSPENSION COLLAPSED.THIS PRELIMINARY EVALUATION HAS BEEN UPGRADED TO AN ENGINEERING ANALYSIS TO FURTHER INVESTIGATE THIS ISSUE, TO ASSESS THE SAFETY-RELATED CONSEQUENCES, AND TO DETERMINE THE SCOPE OF THE AFFECTED POPULATION.
Suspension:front:control Arm:upper Ball Joint
ODI OPENED PE04-040 BASED ON THREE CONSUMER REPORTS OF ALLEGED BALL JOINT FAILURE.THE COMPLAINTS ALLEGE THAT A FRONT SUSPENSION BALL JOINT SEPARATED WHILE DRIVING, WHICH CAUSED THE SUSPENSION TO COLLAPSE AND RESULTED IN A LOSS OF VEHICLE CONTROL.ALL OF THESE COMPLAINTS INVOLVED THE FAILURE OF A LOWER BALL JOINT.DURING THE INVESTIGATION, TOYOTA IDENTIFIED A TOTAL OF 15 COMPLAINTS OF LOWER BALL JOINT SEPARATION, ONE OF WHICH RESULTED IN A CRASH, AND 28 WARRANTY CLAIMS RELATED TO LOWER BALL JOINT WEAR.ODI'S ANALYSIS SHOWED THAT OF THE 15 SEPARATIONS, 11 WERE ON FOUR-WHEEL DRIVE VEHICLES (24.2 PER 100,000 VEHICLES), WHICH MAKE UP APPROXIMATELY 40% OF THE 2002 MY POPULATION (45,448 VEHICLES).ODI'S ANALYSIS ALSO SHOWED THAT SOME DRIVERS LOST FRONT BRAKING ABILITY AS THE BRAKE LINE SEVERED WHEN THE FRONT SUSPENSION COLLAPSED.THIS PRELIMINARY EVALUATION HAS BEEN UPGRADED TO AN ENGINEERING ANALYSIS TO FURTHER INVESTIGATE THIS ISSUE, TO ASSESS THE SAFETY-RELATED CONSEQUENCES, AND TO DETERMINE THE SCOPE OF THE AFFECTED POPULATION.