2004 Toyota Tacoma Problems

What owners report

Owners of this model year most often report rust-related problems, especially frame and underbody corrosion that is typically discovered during inspections, oil changes or tire work. Ball joint and wheel-detachment complaints also appear in the sample, and many surface at higher mileage on older trucks.

1. 1
   Body and structure

   Frame rust and perforation

   • 247 complaints (60%)
   • median 120,000 mi at 12.0 yrs old (183 state mileage)
   • 5 mention a crash, fire or injury
   • owner-quoted repair $2,375 (median of 10 quotes)
   • filed 2005–2026

   Complaints describe frame rails, subframe sections and the area around the rear leaf spring mounts rusting through, with holes, cracks and pieces flaking off. Several owners say the truck failed state inspection or was refused as a trade-in, and that dealers diagnosed a need for full frame replacement. Owners also report being told the vehicle was not covered or that a frame warranty period had expired. Mostly reported between roughly 90,000 and 235,000 miles on older trucks, often in states that use road salt.

   Recall 12V5420003 related service bulletins

   What to check: Have the frame inspected on a lift, paying attention to the rails above the rear tires, the leaf spring mounts and the spare tire area. Ask for any records of frame inspection, rust treatment or frame replacement.

   2 excerpts from owner complaints in NHTSA records

   “The body frame of my Toyota is rusted and I was told by the dealership that Toyota contacted the owners of the vehicles (effected years) to have the frames replaced. I have not be contacted by Toyota about the rust and corrosion on my truck and the rust is very bad. I was told that if the frame cracks while driving, it's a major safety issue. Please help!”

   NHTSA complaint #10734653, filed 2015-07, 65,805 miles

   “3 years ago Toyota sent us a noticed and called .. Asking us to have our frame inspected due to frame failures and rust. We complied and had the undercoating and frame inspected for 3 years with the understanding that this would protect us if future frame problems were identified. This year 2012 we were told we didn't need to have the frame inspected, however when we were replacing the brakes we noticed significant rust on the frame of the vehicle. …”

   NHTSA complaint #10502145, filed 2013-03, 109,400 miles
2. 2
   Suspension

   Lower ball joint failure and wheel detachment

   • 51 complaints (12%)
   • median 119,938 mi at 10.8 yrs old (42 state mileage)
   • 5 mention a crash, fire or injury
   • filed 2004–2026

   Complaints describe front lower ball joints wearing or separating, sometimes letting the tire and wheel come away from the vehicle at low or highway speeds. Owners often mention little or no warning, at most a tight or wandering steering feel beforehand, and report control arms, tie rods and ball joints being replaced afterward. Some say the dealer declined coverage under the ball joint campaign for their vehicle. Reported from about 22,000 miles up to over 250,000 miles, at a mix of city and highway speeds.

   Recall 05V2250001 related service bulletin

   What to check: Ask whether the front lower ball joints and control arms have been replaced, and have a mechanic check them for play before purchase.

   2 excerpts from owner complaints in NHTSA records

   “The lower ball-joint on the drivers front failed while driving (approx 20mph on a straight, smooth residential road (fortunately unloaded truck and at low speeds) sending the wheel sideways and slamming the suspension arm into the ground, where I skidded for about 40-50 feet. There is a recall in effect for this problem, year, make, model, mileage range, but only the 4 wheel drive models and 4 runners. It needs to be extended to the 2 wheel drive models as well. I had very little indication that something was wrong. …”

   NHTSA complaint #10873888, filed 2016-06, 163,000 miles

   “Takata recall, I am writing this complaint because I own a 2004 Toyota Tacoma . On november 2nd I was driving home , was at a 4way stop, once it was my turn to go I accelerated as usual and had my tire on the drivers side detach completely from the ball joint causing me to nearly wreck my truck, if I had been going faster I would have, this was one of the most scariest experiences I have ever had driving! It cost me nearly 1000.00 dollars to fix and now I am having to have the other passenger side fixed because the mechanic says it's hammered.. …”

   NHTSA complaint #11244235, filed 2019-08, 269,000 miles
3. 3
   Fuel system

   Fuel tank straps and tank corrosion

   • 17 complaints (4%)
   • median 104,500 mi at 10.7 yrs old (16 state mileage)
   • 1 mention a crash, fire or injury
   • filed 2005–2023

   Owners describe the metal straps and shield holding the fuel tank rusting through, letting the tank drop toward the road or drag, sometimes with a rattling noise before it happens. Complaints also mention fuel smells and leaks from a corroded tank, and dealers replacing the tank or straps after the failure. Mostly reported between roughly 15,000 and 165,000 miles, generally on older trucks in salt-belt areas.

   Recall 12V542000

   What to check: Inspect the fuel tank straps, shield and spare tire carrier plate for rust, and ask whether the tank or straps have been replaced.

   2 excerpts from owner complaints in NHTSA records

   “While on a short shopping trip I suddenly heard a loud rattling/buzzing noise coming from underneath the vehicle. I drove to my local car repair where they noticed while I was pulling into their driveway that the truck fuel tank was bouncing dangerously and was on the verge of falling off. Both the fuel tank holder ( a large steel plate ) and the fuel tank strap had rusted thru and were no longer supporting the tank. I shudder to think what might have happened if the tank had fallen. …”

   NHTSA complaint #10701148, filed 2015-03, 69,715 miles

   “Gas tank shield corroding when notified by Toyota about corrosion problems to the frame of the truck, I inspected the under neath of the truck myself and also noticed the gas tank shield had corroded away. When I went to the dealer to have the frame checked, I told them about the problem with the gas tank shield and they told me that was not part of the recall.now a year later, I just received another recall for a different problem, excessive corrosion of the spare tire carrier plate . …”

   NHTSA complaint #10491715, filed 2013-01, 122,000 miles

Buying note. Rust inspection is the main thing to arrange before buying this model year, since frame and underbody corrosion come up far more than anything else in the complaints. Also have the front ball joints and the fuel tank mountings checked, and ask for service records covering both.

Summary written with AI from a sample of 60 NHTSA complaints for this model year (picked at random, with complaints that state a mileage and recent ones taken first), then checked automatically against the source records. Where a problem shows a complaint count, every complaint for this model year was matched with fixed keyword rules (written with AI and tested against the sample), and the mileage, age and repair figures are calculated from those complaints; owners' figures are as stated, not verified. Other counts refer to the sample. The excerpts come from NHTSA's public complaint records and are unverified; capitalisation is normalised, NHTSA staff notes are removed, and shortened text ends with “…”. Something wrong? Request a correction.