Which parts fail
Components named in complaints (fuel pump, injectors, fuel tank, hybrid and EV propulsion).
Mileage when the problem started
Owner reports
Selected complaints filed with NHTSA by 2004 Toyota Tacoma owners, lightly cleaned up (personal details are redacted by NHTSA).
The contact owns a 2004 Toyota Tacoma. The contact stated while driving 20 MPH and making a right turn, the vehicle lost motive power and stalled. There was no warning light illuminated. The contact was able to veer to the side of the road. The vehicle failed to restart after several attempts. The vehicle was towed to the dealer, where it was diagnosed that the Electronic Fuel Injection (EFI) main fuse had blown due to a short circuit. The dealer replaced the Electronic Fuel Injection (EFI) main fuse; however, the failure persisted. Additionally, the dealer diagnosed that the subframe was severely corroded, including transmission components and fuel system components. The manufacturer was notified of the failure and informed the contact that they could not assist as unknown recalls had expired. The vehicle was not repaired. The failure mileage was approximately 150,000.
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. …
My pickup was just reframed under Toyota recall at Toyota of bedford,ohio. But,, they omitted the safety shield under the fuel tank.. Aka ..gravel shield.. First saying it never had one, then it was missing, then it didn't come in the kit, I filed a case with Toyota USA, corporation # 1701033889 as per all safety items were to be maintained or replaced !! But I was denied by Toyota corp. So I will have to pick up my truck under protest as Toyota of bedford is threatening me with calling the loaner car in as stolen if I don't today ! Said shield was "rusty" but most was on the truck when it went in there, and im on social security (small check) which our great obama care takes almost five eights of & I really cant afford the $ 640.- they are asking just for the part ! …
The owner found a recall on 2004 Toyota tacomas on the internet. This recall specified that there was a manufacturing defect in the formulation of the undercoating. This manufacturing defect resulted in the rusting of the suspension, and tire plate. Upon inspection of the vehicle by a Toyota dealer, it was found that the a-frame is rusted through, the leaf springs are failing and are bowed in the opposite direction, gas tank mounts are rusted and the under body of the gas tank housing is rusting through. Toyota deemed the vehicle unsafe but refused to do anything because the recall had expired. The owner never received a notice by mail during the recall period. If the owner would have received the recall notice he would have brought the vehicle in for inspection and repair. …
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. Adding insult to injury, this vehicle was in for a recall on 2/13/12 for repair of rust on the frame at miles 52449 ). On 6/18/13 it was in for another recall to fix rust on the rear tire carrier which was replaced ( at miles 61103 ). At neither of these recalls was I told of excess rust on the tank holder and yet with additional mileage of 8612 miles both the fuel tank strap and holder failed. …
Tl* the contact owns a 2004 Toyota Tacoma. The contact noticed an abnormal odor coming from the fuel tank. The contact drove home and parked the vehicle. The following morning, the contact noticed fuel leaking from the fuel tank onto the driveway without warning. The vehicle was towed to an independent mechanic who diagnosed that the fuel tank needed to be replaced. The vehicle was repaired, but the failure recurred. The vehicle was towed to ashland Honda Toyota (2301 lake shore dr e, ashland, wi 54806, [phone]). The dealer ordered the fuel tank and sent it the independent mechanic. The vehicle was taken back to the independent mechanic who diagnosed that the fuel tank needed to be replaced for the second time after one year. The manufacturer was not made aware of the failure. The failure mileage was approximately 130,000.
From a dead stop to any speed, it felt like I no acceration. I would have to feather the gas pedal to get up to speed. I've replaced fuel filter, 02 sender ( front), maf sender ,fuel pressure regulator ,cleaned all grounds, had fuel pump tested , had head gasket checked ,changed spark plugs and wire's, cleaned throttle body and pressure cleaned fuel system. Every time I change a part or do any cleaning , the truck will run fine, for awhile , but the problem returns. I now have 150K on truck ,and I want to get 150 k more. I fell this is a extremely hazards situation. All I'm looking for is a answer to what's wrong!!!! Toyota is aware of what's wrong ,but the dealers only to keep replacing parts ($) . The Toyota forum s on web have 1000s of answer s, but, nothing definite. Please help!!!!
While driving I heard an unusual noise coming from underneath the vehicle. Upon self inspection I discovered the fuel tank strap had broke. I noticed also that the fuel tank shield looked like swiss cheese from corrosion. I had a tie down strap that I was able to use to strap the shield and tank up with. I am in the process of looking to repair it. I feel since it is a safety issue Toyota should fix it free of charge. A fuel tank strap should never fail like this.
Dt:the contact stated the fuel line caught on fire o. While stopping at a red-light he noticed there were flames coming from between the cab and bed of the pickup truck. The fire was extinguished, and the vehicle was towed to the dealership. The dealership had the vehicle for nine weeks. The vehicle has been repaired, and is ready to be picked up. The cause of the fire was from the fuel line and the seal of the fuel tank.
Driving at 35 MPH, hear a dragging noise and pull to the side of the road. I looked under the car a saw that the metal straps holding the gas tank to the car had rusted thru, allowing the tank to drop down to about 3 inches above the roadway, causing the tank to drag the ground
Fuel System complaints in other Tacoma years
Frequently asked questions
How common are fuel system problems on the 2004 Toyota Tacoma?
NHTSA has 24 complaints about the fuel & propulsion system of the 2004 Toyota Tacoma, 6% of the model year's 414 complaints. The component named most often is delivery (2 mentions).
Is there a recall for 2004 Toyota Tacoma fuel system problems?
No. NHTSA lists no fuel & propulsion system recall for the 2004 Toyota Tacoma, though it has 3 recalls for other components. If the problem is widespread, a repair may still be covered by an extended warranty or a manufacturer service bulletin — ask a dealer.
At what mileage do 2004 Toyota Tacoma fuel system problems start?
Half of the complaints with a recorded mileage happened before about 100,000 miles, and 23% before 25,000 miles.
Is it dangerous?
Owners linked 0 crashes, 1 fire and 0 injuries to fuel & propulsion system problems on this model year. If you notice symptoms, have the car checked before driving further.
Source: U.S. National Highway Traffic Safety Administration (NHTSA) — owner complaints through October 20, 2026, recalls and defect investigations; fuel economy from the EPA. Complaints are unverified reports and are not proof of a defect. How we rate model years.