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 2002 Toyota Tundra owners, lightly cleaned up (personal details are redacted by NHTSA).
The contact owns a 2002 Toyota Tundra. The contact stated that he previously received notification of NHTSA Campaign Number: 09V444000 (Structure). The vehicle was taken to the local dealer and repaired under the recall. Recently, the contact was informed by an independent mechanic that cracks had formed on the rear suspension due to severe corrosion. The contact then took the vehicle to another dealer, Kelly Toyota of Hamburg (1 Industrial Dr, Hamburg, PA 19526), and was informed that the recall was a one-time free repair and the dealer offered no additional assistance. The manufacturer was notified of the failure and informed him that the recall was too old. The vehicle was not repaired. The failure mileage was 81,324.
The contact owns a 2002 Toyota Tundra. The contact stated that while driving at an undisclosed speed, the vehicle began to vibrate, prompting the contact to maintain low speeds. After a visual inspection, the contact observed that the front passenger wheels had a negative toe. No warning lights were illuminated. The vehicle was taken to the dealer, who determined that the lower ball joint had separated from the knuckle. The vehicle was not repaired. After investigating the failure, the contact related it to NHTSA Campaign Number: 05V225000 (Suspension), but the VIN was not included. The manufacturer was notified of the failure but provided no assistance. The failure mileage was 249,000.
Was told about the recall awhile ago and they said that my frame was ok. But now I have a perfectly good truck in good condition other than a rusted frame. Had some work done and mechanic said it is unsafe to drive due to rusted frame. They know of the defect and only replace a few and it looks like others are dealing with what I am.
The frame on the truck is rusted out with holes through it and the metal is rusted out along the entire frame. The truck vibrates when driving and when inspected by the dealer, Kari Toyota, they advised it is unsafe to drive as the frame could break entirely and cause an accident. Report is attached. Toyota was contacted on several occasions by Kari Toyota and myself in May and June of 2021. I had the vehicle in for repair of the frame rust issue on June 15, 2012 but clearly the work was not done properly as the rust issue continued until the vehicle is now undriveable. The vehicle has only 106,681 miles which is low for a typical Toyota vehicle. Toyota refuses to repair the vehicle even though I had followed up on my end by bringing it in for the recall repair. I requested a letter from Toyota explaining why they won't cover the repairs and they refused to send one.
First the gas tank let loose and fell half way off. Result was a new gas tank installed. then part of the frame rusted from the cab. This resulted in having to have it welded. Have had several service repair lights come on that resulted in more fixes. Today just about does it. The spare tire fell to the road because rust ate through what was holding it up. I have all the papers that show the repairs and what it has cost me. I have not done anything yet about spare tire. I have had the truck since 2013 and it has less then 94k miles on it. It had 35 when I bought it and I knew nothing about the rust problem recall. I certainly believe I should have a new frame or some kind of compensation. Over the years I have talked to several dealers that got me no where. I guess this is my last shot.
on June 9th at about 2pm while driving through my neighborhood, my upper an lower ball joints on my 2002 Toyota Tundra separated from my vehicle causing a catastrophic loss of control of truck and tore my hub with tire from vehicle ripping the brake fuel line and shoving entire components up under my Tundra while losing control with no brakes or steering capability. It also destroyed the drivers side front tire. Needless to say if I was say...going 55 to 60 miles per hour on highway...I would not be writing this. Had truck towed to Checkered Flag Toyota and they quoted me a price of over1300$ in repairs... they are fighting me on fixing my truck damages even though said damages were caused by the ball joint recall on the 2002 tundra...recall I D#05v
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.
I have owned a 2002 Toyota Tundra 4x4 since 2002. In July of this year I experienced a near wreck when I hydroplaned and was unable to regain control. When I tried to gain control I felt as if the truck was going to roll and I was forced to drive off the highway. Although I did not collide with anything I did have some damage to the rear axel with noises coming from it. The next day I took the truck to a local garage to inspect the vehicle and they found nothing. Not stopping there I crawled under and I found a broken link bolt on the right front sway bar. Upon inspection of the link bolt I found that the link had rusted to less than half of it's original diameter which lead to its failure. Taking this issue up with a Toyota dealer I had them repair both sides of the sway bar links. When the left link was removed it too was found to be broken. …
While traveling on a city road at about 25 MPH, the right front wheel came off. I was towed to my mechanic for repair. Both the tow driver and my mechanic told me they had seen this previously in Toyota Tundra's. I later found that there was a recall (ssc 50 j) and, after email correspondence with Toyota and dealership approval of the workmanship performed by my mechanic, applied for a refund of my expenses. When I was denied the first time, the service manager at hollywood Toyota said that he would resubmit by fax, saying that he saw nothing more that the office could want and that he had submitted the Toyota service order for his inspection of my truck, a service order which the office claimed they did not have. The claim was denied again, this time because I had no records of maintenance on or inspection of the faulty ball joints. …
My Tundra was recently diagnosed with critical frame damage that will not pass pa. State inspection. The vehicle was serviced by Toyota for most of it,s life and all frame recalls were completed. The truck has 136,078 miles and is in very good condition. My recent claim with Toyota was rejected based on the their interruptation that all required recalls were done and there is nothing Toyota can due for me. There are numerous problems with toyotas response. The first beginning that when I picked the truck up after the frame recall treatment I asked the tech how the frame looked, he said good but there is a separation starting at the driver side rear leaf spring. That is exactly where my problem lies today. I believe Toyota covered up the problem by treating the frames rather then replacing them in an attempt to save money. …
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.
NHTSA investigations
Front suspension ball joint breakage
Odi opened pe04-040 based on three consumer reports of alleged ball joint failure.the complaints allege that a front suspension ball joint separated while driving, which caused the suspension to collapse and resulted in a loss of vehicle control.all of these complaints involved the failure of a lower ball joint.during the investigation, Toyota identified a total of 15 complaints of lower ball joint separation, one…
Ball joint separation
Odi received 3 consumer reports of alleged ball joint separation on my 2002 tundra vehicles.the complaints allege that a front suspension ball joint separated while driving, which caused the suspension to collapse and resulted in a loss of vehicle control.based on these complaints, odi opened pe02-040 and later upgraded to ea04-024 for my 2002 tundra vehicles.during ea04-024, additional failure data was identified…
Suspension complaints in other Tundra years
Frequently asked questions
How common are suspension problems on the 2002 Toyota Tundra?
NHTSA has 81 complaints about the suspension of the 2002 Toyota Tundra, 17% of the model year's 482 complaints. The component named most often is front › control arm › lower ball joint (32 mentions).
Is there a recall for 2002 Toyota Tundra suspension problems?
Yes — NHTSA recall 05V-225 (lower ball joint, May 17, 2005). Recall repairs are free at authorized dealers.
At what mileage do 2002 Toyota Tundra suspension problems start?
Half of the complaints with a recorded mileage happened before about 110,000 miles, and 7% before 25,000 miles.
Is it dangerous?
Owners linked 11 crashes, 0 fires and 6 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.