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In 2008, Toyota proactively announced a 15-year, unlimited-mileage corrosion warranty for 1995–2000 model years due to inadequate rustproofing and frame corrosion issues affecting over 800,000 Tacomas. Toyota will either repair the frame or buy back the truck for 1.5 times its KBB retail value.
The Tacoma pickups were built between mid-December 2009 and early February 2010. Most affected vehicles have not been sold. [104] Another recall for frame corrosion recall was confined to the following model(s): [105] MY 2000–2003 Toyota Tundra. According to Toyota USA, frame corrosion could allow spare tires or the fuel tank to fall off the ...
Replacement frame due to excessive rust on a 2000–03 Tundra. During late 2009, Toyota issued a recall on 2000-2003 model year Tundras regarding rust problems of a rear crossmember. This recall involved 110,000 vehicles and followed a similar action for the Tacoma. Tundra owners began complaining of rust issues.
[citation needed] If a car is body-on-frame, then the frame (chassis) must also be rustproofed. In traditional automotive manufacturing of the early- and mid-20th century, paint was the final part of the rustproofing barrier between the body shell and the atmosphere, except on the underside.
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Second big problem: GM's cost-cutters decided not to fit a water separator. Unlike gasoline, diesel fuel is subject to water condensation – hence the need for a water separator. Without one, water in the fuel becomes water in the engine, where it can rust either the cylinders or the complicated mechanical fuel injection pump.
Toyota was also forced to pay a total of $66.2 million in fines to the Department of Transportation for failing to handle recalls properly and $25.5 million to Toyota shareholders whose stock lost value due to recalls. Nearly 400 wrongful-death and personal injury cases were also privately settled by Toyota as a result of unintended acceleration.