2004 Toyota Tacoma

2004 Toyota Tacoma Regular Cab

Overall

Not Rated

Front Crash

Not Rated

Side Crash

Not Rated

Rollover

★★★☆☆

2004 Toyota Tacoma Double Cab

Overall

Not Rated

Front Crash

Not Rated

Side Crash

Not Rated

Rollover

★★★☆☆

2004 Toyota Tacoma Extended Cab

Overall

Not Rated

Front Crash

Not Rated

Side Crash

Not Rated

Rollover

★★★☆☆

TIRES:TEMPORARY/EMERGENCY SPARE TIRE

Toyota is recalling certain model year 2001 through 2004 Tacoma light trucks manufactured from August 28, 2000, through August 27, 2004, and originally sold, or currently registered, in the following cold climate states with high road salt usage: 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. The spare tire in the subject vehicles is located underneath the rear of the vehicle and held by a spare tire carrier. A lift plate on the carrier is used to help raise, lower and retain the tire. During its manufacture, the lift plate may not have been sufficiently coated with anti-corrosion materials. If the plate is insufficiently coated and the vehicle is operated in cold climate regions where road salts are frequently used, road spray can reach the carrier assembly and corrode the lift plate.

Campaign: 12V542000

EXTERIOR LIGHTING

CERTAIN AJ MOTORSPORT COMBINATION LAMPS SOLD AS REPLACEMENT LAMPS FOR USE ON THE ABOVE LISTED PASSENGER VEHICLES. COMBINATION LAMPS NOT EQUIPPED WITH AMBER SIDE REFLECTORS FAIL TO CONFORM WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED EQUIPMENT.

Campaign: 06E065000

EXTERIOR LIGHTING

CERTAIN PRO-A MOTORS CORNER LAMPS, TURN SIGNALS, AND HEADLIGHTS SOLD AS REPLACEMENT LAMPS FOR USE ON CERTAIN PASSENGER VEHICLES LISTED ABOVE. SOME COMBINATION LAMPS THAT ARE NOT EQUIPPED WITH AMBER SIDE REFLECTORS FAIL TO CONFORM TO FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED EQUIPMENT.

Campaign: 06E026000

SUSPENSION:FRONT:CONTROL ARM:LOWER BALL JOINT

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.

Campaign: 05V225000

SEAT BELTS:FRONT

CERTAIN PICKUP TRUCKS FAIL TO CONFORM TO THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 209, 'SEAT BELT ASSEMBLIES.' THE DRIVER'S SIDE SEAT BELT HAS INCORRECT MARKINGS.

Campaign: 04V214000

STRUCTURE

Immediately after the manufacturer recall requiring full frame replacement (completed November 2017 by the same dealership referenced below), the vehicle developed abnormal handling not present before the repair, including improper tracking and rear end instability. No warning lights/diagnostic messages were present. These issues were reported to the servicing dealership within weeks and repeatedly over the following years. Despite multiple short initial inspections and two extended service periods—totaling approximately fourteen months in the dealership’s possession—the dealership repeatedly reported no defect found and continued to advise that the vehicle was safe to operate. Due to ongoing safety concerns, an independent inspection was recently obtained. It confirmed measurable rear axle offset and a thrust angle deviation outside acceptable tolerances. The defect is visually apparent: the rear wheels are not symmetrically aligned, and the vehicle exhibits a noticeable “crab walking” effect when viewed from behind. The root cause remains undetermined and would require further diagnostic work and significant disassembly. All documentation and inspection findings are available upon request. Safety risk: The vehicle does not track correctly and shows instability, especially in low traction conditions such as rain or snow, increasing the risk of loss of control. The manufacturer has been formally notified through repeated outreach, including ongoing contact with the Brand Engagement Center since December 2025 and multiple certified letters to Toyota North America Legal/Consumer Affairs between January and March 2026. The only response received was a generic statement from the Brand Engagement Center indicating that the vehicle is out of warranty and an offer to return it to the same dealership that performed the frame replacement and failed to identify the defect. No other response, investigation, or resolution has been provided by Toyota North America.

SUSPENSION

I was turning into a gas station and all the sudden the vehicle came to a complete stop i was unable to move the vehicle and sat there until the tow truck was able to show up. Looked under the vehicle and on the passenger side front suspension the lower ball joint was no longer where it belongs.

POWER TRAIN

My 2004 Toyota Tacoma was part of the frame replacement back in the fall of 2018 when Bobby Rahal Toyota in Mechanicsburg, PA has by truck for over 6 months while they replaced my frame.  It has been determined that my rear differential is rusted and is now to the point of needing replaced.  For over the last year I have tried working with Bobby Rahal to come to and understanding on having this repaired due to the fact that my mechanic believes that this rust is in fact the same issue as the frame and should have been replaced when the frame was.  All they will tell me is that the recall is closed and there is nothing they can do.   Very disappointed in the fact that this was handled when it should have been.  Now I am stuck trying to figure out how to pay for this myself.  I have taken very good care of my truck for over 21 years and there is no reason for me to have to pay out of pocket for something that they should have taken care of during the recall.  I don't have a lift to check the underneath of my truck, I trust when there is a recall that the dealership will do its job and fix everything safely and not put an unsafe vehicle back on the road and wait until a vehicle rusts completely through.  Bobby Rahal was also inspecting the truck at this time so they knew the rear differential was rusted.  My current mechanic said the Rear differential has been rusted since the time they replaced the frame and and has been for many years.   It is irresponsible for Bobby Rahal Toyota to have not replaced the Rear differential axel knowing it was rusted and unsafe. 

STRUCTURE

The frame broke

TIRES

The contact owns a 2004 Toyota Tacoma equipped with Toyo Tires, Tire Line: Open Country HT, Tire Size: 265/70/R16, DOT Number: CXLJA881918. The contact stated while driving at various speeds, the steering wheel was shuddering significantly. The vehicle was taken to Walmart for the tires to be balanced and the wheels rotated. The mechanic informed the contact that the service could not be performed because the front tires were out of round, the tires belts were separated, and the tire beads were fractured. The tires were not replaced. The tires were replacement tires. The manufacturer was notified of the failure and informed the contact that the tire warranties were not transferable from the previous owner. The vehicle failure mileage was approximately 144,549. The tires failure mileage was approximately 20,000. The VIN was not available.

UNKNOWN OR OTHER

I am writing to report a safety related issue with a 2004 Toyota Tacoma that I purchased from an auction on 12/21/2022. The vehicle has an expired recall that I believe has not been properly addressed, potentially affecting the safety of the vehicle. I have attempted to resolve this issue through Toyota's customer service and local dealership, but I have been informed that the recall is no longer active and will not be addressed. It has a Virginia rebuilt title. It failed inspection due to rust on the frame.

SUSPENSION,STRUCTURE

The vehicle has an open recall (NHTSA Recall #12V542) for the spare tire carrier lift plate. I brought the vehicle to a Toyota dealership to have the recall addressed, but the dealership refused to perform the repair, stating that the frame is too rusted to proceed safely. They recommended a full frame replacement due to severe rust damage, which includes holes and significant structural weakening. Toyota has refused to provide a replacement frame under any existing recall or warranty program. This means the recall cannot be completed, and the vehicle remains unsafe to drive. Additionally, I cannot locate a replacement frame for this vehicle through Toyota or the aftermarket, leaving no practical solution to address the safety risks. The refusal to honor the recall and the lack of available replacement parts put me and others at significant risk. The problem has been confirmed by the Toyota dealership during inspection, and the rust damage makes the vehicle structurally unsound. The unresolved recall, combined with the excessive frame rust, has created a double safety hazard that needs urgent resolution

UNKNOWN OR OTHER

Bringing to your urgent attention a significant safety concern regarding a 2004 Toyota Tacoma owned by my brother, [XXX] , bought in 2004, which has severe frame rust affecting the vehicle’s structural integrity and safety. Despite multiple attempts to resolve this matter directly with Toyota, we have been unable to obtain assistance, as Toyota states the Customer Support Notice for this issue has expired. Given the potential risk this poses to both the driver and other motorists, we are seeking your intervention to address this pressing matter. In September 2024, while retrieving an item from under the truck, my brother discovered extensive rust damage on the vehicle’s frame. We promptly took the truck to Antwerpen Toyota on September 4, 2024, where a technician confirmed the severe rust corrosion and deemed the truck unsafe to drive. The dealership informed us that Toyota had previously issued a Customer Support Notice addressing rust issues on this model but explained that the program had expired. They recommended we contact Toyota directly for potential support or compensation to help acquire a safe vehicle. We reported the case to Toyota (Case No. [XXX]) on September 4, 2024, and have since been in regular contact, yet have only been met with repeated delays and dismissals. Toyota representatives acknowledged that a notice had been issued for this problem, but despite knowing the serious nature of the rust and its impact on the vehicle’s safety, they have not provided us with any solution. We have requested escalation to senior management, but those requests have not been honored. Toyota’s refusal to address this safety defect, even with our willingness to discuss options, has left us with no alternative but to turn to your agency for help. We understand that the notice has expired and that my brother was not the vehicle’s original owner. However, this issue goes beyond a typical warranty claim, as it concerns the fundamental safety and road. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

STRUCTURE

Vehicle was taken to dealer with frame rust, crack and holes. Toyota refused to fix , repair or offer parts to repair.

SUSPENSION,SERVICE BRAKES,FUEL/PROPULSION SYSTEM

2011- check engine light was illuminated. Toyota dealership attempted repairs 11 times but could not find a cause. They replaced 7 different sensors, replaced gas cap, charcoal filter.. still could not get light to go off. refused to continue servicing same issue with no fault. Since 2011, I have had to run diagnostics on a regular basis to ensure there are no other mechanical issues. 2022- gas tank fell off of truck while driving. The straps snapped off due to rust and tank fell to the ground. This issue could have caused GREAT bodily injury or DEATH. 2023-lost brakes while driving. TOTAL brake failure. local mechanic stated it was a proportioning valve failure. The housing for it was rusted through and cannot be removed safely. After multiple days of research, a replacement could not be located. Even contacting Toyota, part is unavailable so vehicle CANNOT be fixed. Total brake failure could have led to GREAT bodily injury or DEATH. ONGOING-- vehicle frame is extremely rusted. bumper has fallen off, spare tire fell off, brush guard rusted and fell off. The frame under cab near bed of truck is rusted through. gas tank straps rusted through and tank fell off. You can literally push fingers/hand through the flaking metal. ALL previous recalls were completed including undercoating but the rust has gotten so bad the vehicle is not safe to drive.