Which parts fail
Components named in complaints (struts, shocks, control arms, ball joints, springs).
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 had taken the vehicle to Kolosso Toyota (3000 W Wisconsin Ave, Appleton, WI 54914) to have his exhaust replaced. While there, he was informed that the entire sub frame was corroded with several cracks and holes had formed around both front leaf springs. The mechanic informed him that the vehicle was unsafe to drive due to the failure. Prior to the failure, the contact took the vehicle to another local dealer where the vehicle was inspected under NHTSA Campaign Number: 05V225000 (Suspension). The contact was informed that a special coating was sprayed onto the sub frame to prevent corrosion; however, the recall remedy failed to prevent the corrosion. The manufacturer was contacted but provided no assistance. The vehicle was not repaired. The failure mileage was 51,641.
The contact owns a 2004 Toyota Tacoma. The contact stated that while driving approximately 55 MPH, the passenger's side axle fractured and the wheel detached. There were no warning lights illuminated. The vehicle was towed to an independent mechanic who replaced the ball joints. The local dealer was not contacted. On another occasion, while driving at an undisclosed speed, the driver's side axle fractured and the wheel detached. The vehicle was towed to an independent mechanic who replaced the ball joints however, the failure recurred. The contact stated that the failure was related to NHTSA Campaign Number: 05V225000 (Suspension). The manufacturer was contacted but provided no assistance. The approximate failure mileage was 190,000.
The contact owns a 2004 Toyota Tacoma. The contact stated while driving 70 MPH and making a right turn, the front passenger's side tire and wheel inadvertently detached from the vehicle. The contact was able to veer to the side of the road, where he noticed that the lower control arm had detached from the subframe and was resting on the floor. The vehicle was towed to the contact's residence. The dealer was notified of the failure and advised the contact that the vehicle could not be repaired under the NHTSA Campaign Number: 05V225000 (Suspension) because the VIN was not included in the recall. The manufacturer was not notified of the failure. The vehicle was not diagnosed nor repaired. The approximate failure mileage was 250,000.
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. …
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. …
I was driving home from a neighboring city after picking up a friend and on my way there on the interstate I noticed the back end of the vehicle was very loose. Upon arriving at my apartment and parking the vehicle I contacted a friend who was a prior state safety inspector, he looked under the vehicle and said the frame right where the shackle for the leaf spring on the driver's side had completely blown out and was no longer connected. Checked the passenger side and said it was connected by maybe 1/4 of an inch of frame. I was made aware of a safety recall that expired back in 2019 by Hailey Toyota and was informed they would not fix it for free. Neither myself or the original owner had every received documentation regarding this issue and was never informed that the entire frame had to be replaced under the recall/extended warranty. …
This vehicles frame has rusted and broken. I feel lucky to have made it home just as the frame cracked wide open on one side making the truck un-drivable. Had this happened on the freeway or somewhere out in a rural setting I may have been killed, caused a problem for other drivers or been stranded away from any help. I have sent a photo of the damage to a frame shop but an independent inspection is not, in my opinion, needed since the rusted, broken member is clearly visible to any lay person. There were no warning lights or anything associated with this problem. What I did feel was some serious shaking and bumping as I moved down the road toward my house.
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.
Tl* the contact owned a 2004 Toyota Tacoma. The contact stated that the vehicle experienced severe corrosion on the frame. The vehicle was taken to the dealer where it was diagnosed that the frame needed to be coated with an anti-corrosive adhesive. The vehicle was involved in a crash while being operated at 2 MPH. A police report was filed. The vehicle was towed to a salvage yard and deemed destroyed. The vehicle was repaired. Upon inspection, it was noticed that there were holes in the frame. The vehicle was taken to the dealer where it was diagnosed that the frame needed to be replaced. The vehicle was not repaired due to it having a rebuilt title. The manufacturer was notified of the failure. There were no injuries. The failure mileage was approximately 115,000.
The lower ball-joint on the drivers front failed while driving (approx 20mph on a straight, smooth residential road (fortunately unloaded truck and at low speeds) sending the wheel sideways and slamming the suspension arm into the ground, where I skidded for about 40-50 feet. There is a recall in effect for this problem, year, make, model, mileage range, but only the 4 wheel drive models and 4 runners. It needs to be extended to the 2 wheel drive models as well. I had very little indication that something was wrong. It started feeling odd, like the alignment was off, and I was driving about a quarter of a mile to safely park it until it could be looked at, when it suddenly failed.
Related recalls
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.
Remedy: Dealers will replace the front suspension lower ball joints free of charge. The recall began on July 5, 2005. Owners May contact Toyota at 1-800-331-4331.
Suspension complaints in other Tacoma years
Frequently asked questions
How common are suspension problems on the 2004 Toyota Tacoma?
NHTSA has 84 complaints about the suspension of the 2004 Toyota Tacoma, 20% of the model year's 414 complaints. The component named most often is front › control arm › lower ball joint (5 mentions).
Is there a recall for 2004 Toyota Tacoma suspension problems?
Yes — NHTSA recall 05V-225 (lower ball joint, May 17, 2005). Recall repairs are free at authorized dealers.
At what mileage do 2004 Toyota Tacoma suspension problems start?
Half of the complaints with a recorded mileage happened before about 120,000 miles, and 9% before 25,000 miles.
Is it dangerous?
Owners linked 7 crashes, 0 fires and 0 injuries to suspension 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.