NHTSA Complaint #11700437 — 2022 TOYOTA TUNDRA

What component failed and is it available for inspection? The front driver-side roof seam on my 2022 Toyota Tundra developed corrosion under the paint and eventually opened enough for rainwater to enter the cabin. Water drips directly into the A-pillar area onto the side curtain airbag wiring, squib connector, and padded harness. It also reaches the dashboard and electrical buttons near the steering wheel during rain. The roof seam, A-pillar wiring, interior rust staining, and all affected components remain available for inspection. How was safety put at risk? The A-pillar contains the SRS curtain airbag system, its wiring, and connectors that should never be exposed to moisture. Continuous water intrusion over many months can cause corrosion, increased resistance, short circuits, or damage to the airbag inflator/squib circuit, which may lead to unintended deployment or failure to deploy in a crash. Water reaching the dashboard controls and electrical switches could cause intermittent electrical faults or malfunction of driver controls. These issues present a significant safety risk because the vehicle’s airbag and electrical systems may not function as designed. Has the problem been reproduced or confirmed? Yes. The Toyota dealer has repeatedly observed the active leak, interior rust streaks, and bubbling/corrosion along the roof seam. The water intrusion occurs every time it rains. Has the vehicle been inspected? Yes. Toyota has inspected the truck multiple times, including by a Field Technical Specialist. However, Toyota has been unable to provide complete documentation or photos from the FTS inspection, and the underlying safety issue remains unresolved. No inspections have been done by police or insurance. Warning lamps or messages? No warning lamps appeared. The first symptom was water leaking into the cabin around March 2024, followed by rust streaking inside the A-pillar and exterior bubbling. The issue continues during rainfall.