NHTSA Complaint #11682040 — 2009 TOYOTA TACOMA

Vehicle: 2009 Toyota Tacoma VIN: [XXX] Mileage: 128,400 Owner: Jacob Grove, Anderson, SC Summary of Issue: The frame of this 2009 Toyota Tacoma has developed severe rust perforation that makes the vehicle unsafe to drive. My independent mechanic has refused to work on it due to safety concerns, and Toyota of Greenville (SC) has confirmed that the frame is extensively corroded and requires replacement. Background: Toyota previously issued a Customer Support Program (CSP) for frame corrosion affecting 2005–2009 Tacomas in northern states, including Ohio, where this truck was purchased and operated. In June 2018, the vehicle was inspected at Don Wood Toyota in Athens, OH (91,600 miles). The dealership recorded “no perforation” and did not apply the protective coating or replace the frame. The truck has been minimally driven since (an average of 6,000 miles per year). In May 2024, at 128,400 miles, a mechanic and dealership confirmed the frame has multiple areas of severe perforation, including around brake lines and exhaust mounts. Concern: It is unreasonable that a vehicle frame could go from “no perforation” to “severe perforation” in only 36,000 miles and six years of light use. This indicates either: The 2018 inspection under Toyota’s CSP was inadequate, or The frame was already compromised but not properly addressed at the time. Safety Risk: The vehicle cannot be safely lifted, worked on, or driven in its current condition. The rapid deterioration presents a risk of frame failure while driving, endangering occupants and others on the road. Request: I am submitting this complaint so that NHTSA is aware of ongoing frame corrosion failures in 2005–2009 Toyota Tacomas, even in cases where Toyota previously inspected and declined to repair during the CSP period. This case demonstrates that the problem may not have been properly identified or corrected during program inspections, leaving unsafe vehicles on the road. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)