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 2002 Toyota Tundra owners, lightly cleaned up (personal details are redacted by NHTSA).
The contact owns a 2002 Toyota Tundra. The contact, who is an independent mechanic, stated that the fuel tank had detached. The contact stated that the subframe was extremely rusted. There were no warning lights illuminated. The contact stated that the failure was related to NHTSA Campaign Number: 09V444000 (Structure). The contact called the local dealer, but the vehicle was not diagnosed or repaired. The manufacturer was not contacted. The failure mileage was approximately 190,000.
The dealership and Toyota Engagement Center refused to service the 2 recalls that was critical for the truck since October 2025. It was supposed to be including frame replacement and other parts but Toyota Engagement decided to active buy back option and took advantage of low offer to solve the matter which I don't accept.
Tl* the contact owns a 2002 Toyota Tundra. While parking the vehicle, the parking brake did not engage. The contact observed that there was a fuel leak under the vehicle and the frame was severely rusted. The vehicle was taken to a dealer where it was confirmed that the frame was severely rusted and needed to be repaired. The vehicle was repaired under NHTSA campaign number: 09V444000 (structure); however, the failure recurred. Approximately two and a half years later, the contact observed that the frame fractured. The vehicle was not taken to a dealer or repaired. The manufacturer was made aware of the failure. The failure mileage was approximately 218,572.
While driving on state road 27, I starting smelling fuel in the cabin; when I get to my destination, about 7 miles after, I came out with the truck still running, notice a lot of fuel under the truck, I turned off the truck immediately and the flow of fuel gradually stopped.
My 2002 Toyota Tundra truck is not drivable at this time. The truck was brought to Toyota dealership after a local mechanic found fluid leaking from rear differential due to rust/rot. During the dealers inspection, they also noted a gas smell and suspect that the gas tank or gas lines are leaking also. The dealer did a frame inspection and while the whole frame is excessively rusted, the frame passed the recall test because it had not been perforated yet. The dealer did not want to even remove the differential plug because the whole unit was so rusty. I have been under the truck and personally seen the excessive rust on the frame, fuel system, and suspension components. Amazingly, the body panels have little or no rust and in very good condition. During previous dealer visits we were verbally told that the rust was normal. …
I have a 2002 Toyota Tundra that is leaking gas. Initially I noticed a fuel smell when I walked by the truck which progressed to seeing fuel on the ground. If I put too much gas in the truck, over 1/2 tank, you can see the fuel leaking through the 4x4 fuel tank protective cover. I had the truck put on a lift and was told that fuel was leaking from the seam of the tank. I recently took my truck to Toyota in response to the recall re:excessive frame rust and my truck passed that inspection. I have less than 51,000 miles on this truck and I am afraid to drive it on the highway. I have lived in ma for 22 years and have never had a fuel tank problem. On 04/06/10 I took my truck to a required yearly inspection. My check engine light was on and the garage told me that my vehicle had failed the emissions test. …
As part of a recall, my 2002 Toyota Tundra required frame repair for damage due to rust/corrosion, the straps holding the gas tank were rusted and also needed to be replaced. When the replacement of the straps was made, the gas tank which was also rusted and not replaced as part of recall was damaged and a gas leak occurred. I have already been faced with an extremely dangerous situation due to the failure of a cross brace which caused the spare tire to release on the highway; now I am concerned that the faulty gas tank will cause a fire. I have called and visited Toyota numerous times to request assistance but no repair or replacement has been offered.
Tl* the contact owns a 2002 Toyota Tundra. The contact stated that while driving approximately 55 MPH, a loud banging noise was heard from the rear of the vehicle. After stopping the vehicle the contact discovered that the metal fuel tank strap had fractured and was making contact with the drive shaft. The vehicle was diagnosed by the dealer, who discovered severe rusting of the frame. The contact stated that the vehicle was inspected in November of 2011 and a corrosion protection compound was applied to the frame but it did not prevent the defect from occurring. The manufacturer was notified and no solution was offered. The failure mileage was 118,000.
Had frame replaced per recall, 5/2012. Had been smelling gas after fill ups so had airport Toyota, vandalia, ohio - repair while they had truck torn apart- told me the gas tank port was corroded so they put new gasket on. Now I am smelling gas on passenger side. I am taking truck back to Toyota. I am concerned about the corroded gas tank because I had it repaired once before. I believe this problem is just as important as the corroded tank straps that were replaced in 2010. It's not something that is seen easily.
Tl* the contact owns 2002 Toyota Tundra. The contact was traveling 30 MPH when he began to smell gasoline fumes in the interior of the vehicle. The contact further inspected the vehicle and found that the fuel line was dry rotten. The leak had caused gasoline to leak onto the manifold and all over the rear of the vehicle. The contact was concerned of a potential fire hazard. The vehicle was not inspected or repaired. The failure and current mileage was 42,500.
NHTSA investigations
Frame corrosion
This investigation was opened based on 20 reports of model year (my) 2000 and 2001 vehicles experiencing severe corrosion of the frame, resulting in either under-body mounted spare tire separation or rear brake failure.the failure report counts shown above are for my 2000 and 2001 vehicles only.by letter of November 16, 2009 Toyota has notified the agency that it will conduct a safety recall (09v-444) of…
Fuel System complaints in other Tundra years
Frequently asked questions
How common are fuel system problems on the 2002 Toyota Tundra?
NHTSA has 22 complaints about the fuel & propulsion system of the 2002 Toyota Tundra, 5% of the model year's 482 complaints. The component named most often is storage › tank assembly (2 mentions).
Is there a recall for 2002 Toyota Tundra fuel system problems?
No. NHTSA lists no fuel & propulsion system recall for the 2002 Toyota Tundra, 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 2002 Toyota Tundra fuel system problems start?
Half of the complaints with a recorded mileage happened before about 100,000 miles.
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.