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 Tundra owners, lightly cleaned up (personal details are redacted by NHTSA).
The contact owns a 2004 Toyota Tundra. The contact stated while driving 25 MPH, the front driver's side lower ball joint detached, causing the driver's side wheel to separate from the vehicle, and the vehicle lowered to the ground. The vehicle was towed to the residence, where it was diagnosed by an independent mechanic. The mechanic determined that the front driver's side lower ball joint needed to be replaced. The mechanic replaced the front driver's side and passenger's side lower ball joints. The contact stated that the vehicle was previously repaired by an unknown dealer for the same failure. The contact stated that the front driver's side and passenger's side ball joints failed several times while driving and were replaced; however, the failure persisted. …
The contact owns a 2004 Toyota Tundra. The contact stated that while driving approximately 40 MPH, there was an abnormal screeching sound coming from the vehicle. The contact then saw sparks coming from the rear driver's side of the vehicle, and the driver's side rear wheel was turned sideways. The vehicle was pulled over to the shoulder and was later towed back to the residence. The vehicle was taken to an independent mechanic, and the contact was informed that the ball joint, control arms, front suspension, and several other unknown parts needed to be replaced. The vehicle was repaired; however, the failure persisted. The independent mechanic made the contact aware of an unknown NHTSA Campaign Number; however, the VIN was not under recall. The manufacturer was notified of the failure. The failure mileage was approximately 200,000.
The contact owns a 2004 Toyota Tundra. The contact stated that while driving at various speeds, the vehicle was pulling to the right. The vehicle was taken to the local dealer who performed a wheel alignment, but the failure persisted. The cause of the failure was not yet determined. The local dealer and manufacturer were not yet notified of the failure. The failure mileage was 100,000.
Purchased new Toyota Tundra in 2004. Performed rust recall at dealer on 07/22/15. October 2016, brakes failed. Brake line completely rusted. July 26, 2021, Toyota Tundra rejected at state inspection for badly rusted frame. Inspectors were unable to get wheel off to inspect brakes because of rust damage. Took to Toyota dealer on March 9, 2022. They performed airbag recall. Unable to do front suspension lower ball joints recall. Dealer said frame could break when they put it on lift. Dealer said Timeframe to repair frame had expired. Estimate to fix frame over $15,000; Plus would need a lot more parts to go with replacement. Vehicle has approximately 68,500 miles on it.
Brought vehicle in for service and frame is completely rusted through in critical areas where suspension and body mounts are supposed to be mounted. The car is not road worthy and unsafe to drive. I came to understand that there was a recall for these truck frame, however my frame was never replaced. My frame was never treated for rust. This truck has always been maintained and serviced at a Toyota dealership. Now I'm told their is nothing they can do.
The warranty work done on the frame of my Tundra that has since failed. The Bracket holding my SwayBar has broken off the frame and, more importantly, the frame has rusted to the point where there is now a hole in it. These are areas where the warranty work occurred.
Severe rust to the frame of my 2004 Toyota Tundra SR5 double cab. There are holes through the frame. Took it for an oil change and the mechanic told me to be careful. Crawled under the truck and couldn't believe how bad it was.
Informed by Al Serra at 4200 Bay Rd in Saginaw, MI 48603 that there are holes present in the frame that pose a dire safety concern. This is a known issue with this model year, but Toyota says the recall is no longer valid.
My 2004 Tundra has a rusted frame and is presently not drivable. No recall notice was send to me by Toyota, nor were any subsequent calls or mail sent. I have 75k on this truck and want Toyota to honor their safety recall
I had the dealer take my truck in for the frame recall. I asked for them to replace the frame because I was not comfortable with how they were handling it. Per the service record they filled in perforations and "undercoated. I did not believe that filling in existing perforations was the safest way to handle this. After brining the truck to a shop to check the steering we were told that they wouldn't even put it up on a lift. The steering issue was that the rack and pinion steering was literally falling out due to the rusted frame. We drove this vehicle home and parked it. About a week later the spare tire fell out right onto our driveway. Needless to say, I am certain there are many more Toyota trucks out there ready to fall apart on the road. We contacted Toyota corporate several times to try to rectify this mishandling of our recall. We called and sent certified letters. …
Related recalls
Suspension › Front › Control arm › Lower ball joint
On certain trucks and Mini vans, due to possible improper finishing of the front suspension lower ball joint, some ball joints May experience an incidental deterioration of the internal lubrication.
Remedy: Dealers will replace the front suspension lower ball joints. The recall began on February 28, 2007. Owners May contact Toyota at 1-800-331-4331.
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
Lower ball joint separation
The office of defects investigations (odi) opened rq06-005 based on four 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 tension-type ball joint.
Lower ball joint failure
In a letter dated January 18, 2007, Toyota notified NHTSA of a safety defect in model year (my) 2004 through 2006 Toyota tundra and my 2004 through 2007 Toyota sequoia vehicles produced between September 15, 2003 and November 17, 2006 (NHTSA recall no. 07v-013).
Suspension complaints in other Tundra years
Frequently asked questions
How common are suspension problems on the 2004 Toyota Tundra?
NHTSA has 152 complaints about the suspension of the 2004 Toyota Tundra, 33% of the model year's 466 complaints. The component named most often is front › control arm › lower ball joint (46 mentions).
Is there a recall for 2004 Toyota Tundra suspension problems?
Yes — NHTSA recall 07V-013 (lower ball joint, Jan 19, 2007); NHTSA recall 05V-225 (lower ball joint, May 17, 2005). Recall repairs are free at authorized dealers.
At what mileage do 2004 Toyota Tundra suspension problems start?
Half of the complaints with a recorded mileage happened before about 90,000 miles, and 4% before 25,000 miles.
Is it dangerous?
Owners linked 6 crashes, 0 fires and 5 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.