NHTSA Complaint #11292484 — 2003 TOYOTA TUNDRA

ON 12/05/11 NEWARK TOYOTA COMPLETED RECALL SSC90M PHASE 2-CRC APPLICATION TO MY RUSTED FRAME. ALMOST IMMEDIATELY I NOTICE A BONDING FAILURE AND DELAMINATION OF THE CRC APPLICATION. BY NOVEMBER OF 2013 I ASKED THE SAME SERVICE LANE MANAGER, BILL C. AND THE TECHNICIAN THAT PERFORMED THE WORK TO INSPECT THE FAILED APPLICATION. I ASKED THE TECHNICIAN WHY IT FAILED AND HE STATED "I DID NOT PREPARE THE SURFACE CORRECTLY BEFORE I PLACED THE APPLICATION". I APPRECIATED HIS HONESTY BUT WAS TOLD THEN THAT THERE WAS NOTHING ELSE THEY COULD DO ABOUT IT. MY FRAME IS NOW VERY RUSTED SO I ASKED BILL C. TO REINSPECT MY FRAME ON 12/5/19 WHILE MY TUNDRA WAS IN FOR A TAKATA AIRBAG RECALL. WILLIAM TOLD ME THAT HE HAD A MANAGER INSPECT MY FRAME AND THAT NO PERFORATIONS WERE FOUND (PLEASE SEE ALL ATTACHED PHOTOS). THEY DID NOT MENTION THE CATASTROPHIC FAILURE OF THE FRAME C CHANNEL LOWER FLANGES. THIS EXPONENTIALLY EXPANSIVE CORROSION HAS REACHED THE LEAF SPRING BRACKET FLANGE RIVETS (SEE PHOTO 8810); CATASTROPHIC FAILURE OF THE REAR AXLE ASSEMBLY WILL RESULT. I AM A MECHANICAL ENGINEER WITH EXTENSIVE TRAINING AND EXPERIENCE IN CORROSION RELATED FAILURE. THIS FRAME AND VEHICLE ARE UNSAFE! ON 12/21/19 I EMAILED THIS INFORMATION, INCLUDING THE PHOTOGRAPHS AND COPIES OF ALL SERVICE RECORDS, TO THE TOYOTA CUSTOMER CARE CENTER. THEY EMAILED ME BACK ON 12/28/19 AND ASKED ME TO CALL THEM. THE TOYOTA REPRESENTATIVE, JEFFERY M., CALLED MY DEALERSHIP AND TOLD ME THAT THE FRAME WAS NOT PERFORATED SO I AM NOT ELIGIBLE FOR THE FRAME REPLACEMENT RECALL. I ASKED JEFFERY MULTIPLE TIMES IF THE DEALER SAID THE FRAME IS SAFE OR NOT. HE REFUSED TO ANSWER THAT QUESTION AND WOULD ONLY STATE THAT MY FRAME IS NOT PERFORATED. THE NHTSA/TOYOTA 10MM PERFORATION CRITERIA IS INADEQUATE AND THE PHASE 2 APPLICATION BONDING FAILURE EXACERBATED MOISTURE AND ROAD SALT RETENTION.