Frame is rotting out

- New Castle, PA, USA

I was simply parking my 2004 Toyota Sequoia in parking lot space. Left front tire fell completely off the car without any previous warning of pending problems! ball joint catastrophically failed! prior recent new tires and alignment showed no pending problems. Did a check and found many prior ball joint issues for this car and a prior recall years ago. Towed to Toyota dealership in capitola ca. They replaced ball joint and related parts. They charged me lots of money claiming that this vehicle had "previously been recalled and repaired in 2007 so no liability on their part. I called Toyota corporate and complained and was bounced around until a fellow named "garret" told me the ball joints had been "fixed" in 2007 during a recall. Great. Then why do these issues continue? my car is driven only on public streets and there was no warning of this impending failure. The ball joint and related simply failed catastrophically. I take excellent care of this vehicle as I intended on keeping it regardless of mileage. What bs is Toyota pulling when their Sequoia (and other similar Toyota vehicles) continue to catastrophically fail without warning" I wonder how many people died on the freeway etc because of this" I have personally owned and/or family, friends etc. Many cars, trucks etc. Ball joints like brakes, tires hoses etc wear out slowly and give ample warning when they need replacement ie tire wear is increased, steering difficulty etc. Not in Toyota's case. There was no warning at all before the wheel just fell off the vehicle. These catastrophic failures of wheels falling off without warning at any moment are horribly dangerous and yet common knowledge including prior recall(s) and yet they still are allowed to continue. This is ridiculous!

- Aptos, CA, USA

Left front (drivers side) wheel ball joint(s) failed catastrophically causing wheel to fall off and wedge under car while pulling into a parking space. No prior warning, no prior noise, no prior steering issues, no strange tire wear (tires just replaced 6 months ago). Just instant and catastrophic failure!

- Aptos, CA, USA

I have a 2004 Toyota Sequoia. The vehicle has been well taken care of with numerous receipts to prove it. Upon further inspection of the vehicle, I have observed a 'rot' hole in the rear part of the frame. The whole in the frame is approximately the size of a dollar bill and spreading. There are other parts of the frame that will need attention in the future. Toyota has recalled Sequoia model years 2005 and up and have neglected to include the 2004. It is apparent that the 2004 Sequoia is subject to the same faulty frame manufacturing as other models/ years of numerous Toyota's. my vehicle has approximately 137,600 miles on it. I have maintained vehicles from from the 90S that have better frame construction than my Toyota. I believe that the frame on my 2004 Sequoia will need frame patches in the future as well as many other metal components connected to the frame replaced.

- Bourne, MA, USA

We bought it in 2014 with 76K and the frame had recently been coated. Supposedly it was from Texas, and we live in northern Minnesota. The frame looked good and seemed solid, but within a year or two all of the coating fell off revealing very rusty metal. By 3 years (2017) there were holes in the bottom of the frame mainly behind the front tires area, and the rest of the frame is also quite rusty. I had to replace the front sway bar end links but they broke soon after and kept breaking within a few months after repeated replacement due to excessive frame movement. It feels less safe without a functional sway bar attached to the frame and has more body roll with more risk of rollover. The frame is rotting from the inside out, and the rust is spreading like cancer in the surrounding areas underneath. The body has almost no rust at all. I parked it in the winters twice now, hoping to buy time. But I'm counting the days that it will be unsafe to drive anymore. I'm not even sure when to determine when that will be, and am hoping it doesn't have catastrophic failure at highway speeds like others have had with the earlier Sequoias. I bought this for my wife and paid $16000 cash for it. We've put on 60K miles but expected to get many more years out of it being that it is so solid and reliable otherwise. This frame is horrible, and probably would have shown itself a problem sooner, had it not been in Texas most of its previous years. It is wrong that the 01-04 years are excluded from the recall that only covered the 05-08 models, when it is obvious the same problem existed then as well based on so many similar reports. Toyota got money from the frame makers and us customers should be reimbursed for the severely prematurely rusting frames, that will be taking 10 or more years off the life of the vehicle otherwise. Please address and take this problem seriously.

- Carlton, MN, USA

Took 2004 Sequoia to kings Toyota for the airbag recall as well as diagnostic eval of vsc ABS lights issue. Received a phone call that the tech could not determine the electrical problem unless we paid an additional $360 for more time to diagnose and that the frame was rusted through with large holes. Wondered if we wanted to pursue the electrical issue with the larger safety issue with the frame. Original issue occurred with lights coming on (had happened several times previously) followed by the power windows ceasing to work, several hours later the wipers and window seemed sluggish and the car lost all power. Had to jump the car several times to get off the road and then when jumping no longer worked, we had to push the vehicle into a church parking lot. After being told by Mr. Howard that they don't see vehicles come into service with large holes in the frame, I researched online and found that 10S of thousands of Toyota trucks, including 05-08 Sequoias, have been recalled - crc applied and frames replaced as well as Toyota buying back 95-00 trucks with rusted frames for 1.5 times the blue book value. 04 Sequoias mentioned more than 300 times for the vsc, tailgate and rusted frame issues that are prevalent in this model - my vehicle has all 3. spoke with colin, the service manager, who reiterated what I found online. Toyota will do nothing since the recall is closed and did not include the 04 models.

- Middletown, OH, USA

Frame has rust holes and the steering stabilizer mount rusted completely off. Very unsafe ! the rest of the car is in excellent condition so the severity of rust on the frame seems very out of place. This issue is extreme and not normal. Not acceptable from a manufacturer known for its quality systems. Tps six sigma embarrasment in my opinion

- Byron Center, MI, USA

Toyota Sequoia with 139K miles. This SUV had a frame recall in 2014, Toyota dealer applied the paint/epoxy to the rusted frame instead of replacing the rusted frame. The paint peeled off within 6 months of the application. Now the frame is rusted very badly. When driving it makes grinding noises. My mechanic said that because of extensive frame rust, the frame has gotten weaker and is slightly bent. This makes the moving parts touch the other parts of the body/frame resulting in the noises. He suggested replacing the rusted frame.

- Stone Ridge, VA, USA

Entire frame assembly has rusted and vehicle is unsafe to drive. Toyota dealership, upon air bag recall fix, informed me of a recall or warranty repair for the Sequoia rusted frames. Toyota corporate claims they cannot do anything since the "recall' has expired. I never received a notification. Many others have this same issue and Toyota is fully aware of this problem and has recalled other model years for frame replacements. Does someone need to die before we get appropriate action?

- Westford, MA, USA

The rear drivers frame snapped in half. Broke in front of rear wheel. No help from Toyota. So it sits in driveway. Rumor has it a recall is on way.

- South Carver, MA, USA

Front suspension making humming noise all the time while in motion, and vibrstion is felt throughout vehicle, passenger side rear axle seal is leaking causing rotor to smoke. Front driver side caliper piston is jammed.

- Spring Hill, TN, USA

Frame is rusting underneayh to the point where I have had to repair the vehicle control arm which rusted off and broke while driving. My tow hitch mount has rusted off. There are more than 5 spots along the frame where rust has perforated and the frame has visible signs of rot. I had a licensed garage inspect the frame and was told the vehicle is dangerous and that the frame should be replaced. I am having continuous problems with the suspension components rusting out.

- Ashtabula, OH, USA

The entire frame is rusting including the rear differential, suspension and other structural component. The dealer sprayed on a liquid tar but now that is falling off with the rust which was sprayed over.

- Randolph, NJ, USA

Me and my family were driving southeast on highway 280 on the far right lane trying to take junction 85 gilroy when all of a sudden through tire on the front driver side came off and the car just was limp on that side and all I can see was sparks and smoke my whole family was terrified.I was trying with all my strength to control the car and with the will of god I managed to safely stop the car.I step out to see what happened and the tire was stuck under the car and completely of the joint with the brecksame still connected to the tire

- Salinas, CA, USA

Last week, (3/17/16) my neighbor was taking her three children to school in her 2004 Toyota Sequoia. She was traveling on a new road at approximately 30 mph when the front end of the vehicle dropped on driver's side. She thought she had a flat tire so she steered to the side of the road. It appears the driver's side, lower ball joint failed (see photos). I called hendrick Toyota of apex, nc and talked with Mr. John specht (919-335-1678). He checked the VIN and said the lower ball joints had a recall and were changed on Aug. 15, 2007. He also suggested I contact Toyota to request their assistance to cover the cost to repair the vehicle (case no.[xxx]). he advised the vehicle be brought in for the airbag recall too. Vehicle was towed home on a dolly to prevent any damage to the transmission. The vehicle has 215,444 miles and was not used for off-road driving. The vehicle recently passed state inspection with no problems noted about the front end. If the lower ball joints were already replaced in a recall (2007) what did they replace them with, and how did they correct the problem? this failure could have caused a deadly accident at higher speed. When a lower ball joint breaks, the driver can only steer with one wheel.[xxx] 'information redacted pursuant to the Freedom Of Information Act (FOIA), 5 U.S.C. 552(B)(6).'

- Cary, NC, USA

Our situation is virtually the same as many other complaints in your system. Namely that Toyota had our dealer apply undercoat to the frame of our 2004 Sequoia in July of 2013. On Sept. 5 this year went to the dealer for an oil change and tire rotation and after waiting a few hours was informed they did not perform the service as the frame was so bad. Knowing that a neighbor had the same problem and Toyota bought it back I asked about it and was told "that program was over" this is a serious safety issue and upon calling Toyota usa was told they can't do anything. There are numerous complaints similar to this on the nhts website. Why isn't anything being done about this?

- Maynard, MA, USA

The contact owned a 2004 Toyota Sequoia. While driving at approximately 40 mph over a manhole, there was a loud popping sound and the front passenger side wheel folded under the vehicle. As a result, the contact crashed into a ditch on the side of the road. The front passenger sustained injuries to the right knee and required medical attention. A police report was filed. The vehicle was destroyed. The manufacturer was made aware of the failure and stated that the VIN was included in NHTSA campaign number: 07V013000 (suspension). The failure mileage was approximately 175,000.

- Kingsport, TN, USA

Made a left hand turn and the control arm broke off from rusted frame while traveling at about ten mph. Repair center says the vehicle is a total loss, because the frame is not safe, nothing to re-attach control arm to!

- Port Royal, SC, USA

*filed with attorney general of New York* recall was issued on the 2004 Sequoia due to corrosion. On July 25, 2013 we brought our car to the dealership to apply a protective coat and waited a week for the car to be returned to us. We had to return the vehicle, September, 2014, to the dealer with the same problem, the spray was flaking off exposing the rust underneath. The vehicle was sprayed for the second time in one day and that time we were told the vehicle's rear axle trailing arm mount was almost separated from the rear axle housing due to the corrosion and it was recommended to replace the axle. At that time we asked if this could have been to the recall of the corrosion, flat out we were told no. We then proceed to take the vehicle to our personal mechanic for second opinion, October 27, 2014, and he confirmed the axle is damage and the frame of the vehicle is in such poor condition that it must be first addressed before replacing the axle; he also mentioned to us this is the second Sequoia that he had seen with the same issue, along he told us the second spraying was done incorrectly, it was not cleaned out they just sprayed over the flaking protective coat and the rust. Our mechanic said the vehicle should not be used because it is not safe and he is willing to sign an affidavit if necessary.

- Cortlandt Manor, NY, USA

Vsc trac light and trac off lights on. Also service engine light on. Won't shut off. Brake light also comes on and then off for no reason. I see on complaint list this is issue for many years but Toyota refuses to recall vehicles. Maybe not enough injuries or deaths or law suits yet. Not a good way Toyota treats customers. Toyota should recall and fix vehicles that have built in - designed in defects. Very disappointing. Also a couple years ago the front ball joint broke...luckily driving slowly and not on the highway.

- Milford, MI, USA