The 2005 Tundra is a first-generation model (2000-2006) known for solid reliability, but the 4.7L V8 has a catastrophic secondary air injection pump failure mode that destroys engines, and both engine options suffer exhaust manifold cracking. Generally durable if the air pump issue hasn't struck.
Secondary Air Injection Pump Failure Causing Engine Destruction (4.7L V8)
Occasional · high severity
Typical onset: 100,000-180,000 mi
Symptoms: Check engine light with P0418/P0419 codes (secondary air injection), Rattling noise from air pump on cold starts, Sudden catastrophic engine failure: metal fragments from failed pump enter cylinders through air injection ports, Engine knock, loss of compression, metal shavings in oil
Fix: If caught early (pump rattling, codes only): replace air pump assembly and check valves, 2-3 hours labor. If pump disintegrates and contaminates engine: complete engine rebuild or replacement required — pistons, rings, bearings, head gaskets, or short block swap — 25-40 hours labor depending on approach.
Estimated cost: $800-1,200 for early pump replacement; $6,000-12,000 for engine rebuild after pump failure sends debris into cylinders
Exhaust Manifold Cracking (Both Engines)
Common · medium severity
Typical onset: 80,000-150,000 mi
Symptoms: Ticking or hissing noise from engine bay on cold start that quiets as engine warms, Exhaust leak smell in cabin with heat on, Visible cracks in cast iron manifolds, typically at center runners, Check engine light with lean codes (P0171/P0174) from unmetered air
Fix: Replace exhaust manifolds with upgraded aftermarket headers or OEM manifolds. V6 is 4-5 hours, V8 is 6-8 hours due to tight clearances and seized studs. Often requires drilling out broken manifold studs.
Symptoms: Clunking noise over bumps from front suspension, Wandering or loose steering feel, Excessive play when prying on lower control arm with wheel lifted, Uneven tire wear on inside edge
Fix: Lower ball joints are pressed into control arms. Replace ball joints or entire lower control arms (most techs prefer complete arms for labor efficiency). Subject to recalls but many trucks aged out of coverage. 2.5-3.5 hours per side.
Estimated cost: $400-700 per side for complete control arm replacement; $600-1,200 both sides
Transmission Oil Cooler Line Corrosion and Leaks
Common · medium severity
Typical onset: 120,000-180,000 mi
Symptoms: Transmission fluid spots under vehicle near radiator area, Low transmission fluid level on dipstick, Transmission slipping or delayed engagement if fluid level drops significantly, Visible corrosion or wetness on cooler lines at frame rails
Fix: Replace transmission cooler lines from transmission to radiator. Steel lines rust through where they contact frame or are exposed to road salt. Some techs replace with aftermarket braided stainless lines. 2-3 hours labor, includes fluid refill.
Estimated cost: $350-600
Frame Rust and Perforation (Rust Belt Trucks)
Occasional · high severity
Symptoms: Visible surface rust progressing to scaling and flaking on frame rails, Perforation holes in C-channel frame sections, especially rear crossmember area, Failed state safety inspections in salt states, Cracking noises when flexing frame over uneven terrain
Fix: No practical repair for severe perforation — frame replacement is cost-prohibitive. Minor surface rust can be wire-brushed, treated, and coated. Toyota had frame replacement programs for Tacoma/Tundra rust issues but coverage has expired. Inspect thoroughly before purchase in northern climates.
Estimated cost: Not repairable economically; frame replacement $8,000-15,000+ (usually totals the truck)
Transmission Mount Deterioration
Common · low severity
Typical onset: 100,000-160,000 mi
Symptoms: Clunk when shifting from Park to Drive or Reverse, Vibration at idle in gear, Visible sagging or torn rubber on transmission crossmember mount
Fix: Replace transmission mount and crossmember bushings. Straightforward job, 1-1.5 hours labor. Often done alongside other driveline work.
Estimated cost: $200-350
Owner tips
Inspect secondary air pump on 4.7L V8 religiously — address P0418/P0419 codes immediately and listen for pump rattle on cold starts. This is your engine-killer.
Check frame thoroughly for rust perforation before buying, especially rear crossmember and spring hangers on rust-belt trucks. Walk away from significant perforation.
Budget for exhaust manifolds — they will crack. Aftermarket headers prevent repeat failures.
Inspect lower ball joints every 20,000 miles; play in these can lead to wheel separation.
Use quality transmission fluid (Toyota Type T-IV or equivalent) and service every 50,000 miles to maximize transmission life on these 4-speed automatics.
Solid truck if the secondary air pump hasn't grenaded the 4.7L V8 and the frame is clean — check both carefully before buying.
AI-assisted summary drawn from NHTSA recall data, our labor-times database, and platform knowledge. Not a substitute for a pre-purchase inspection on a specific vehicle.
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Tenneco Automotive (DRiV) is recalling certain aftermarket ball joints for 2004-2007 Toyota Sequoia and 2004-2006 Toyota Tundra vehicles, MOOG part number K80521, K80522, NAPA part number NCP2601633, NCP2601634, ACDelco part number 45D2344, and 45D2345. The ball joint housing may have inadequate hardness, causing premature failure.
Consequence: A ball joint failure may cause a loss of control, increasing the risk of a crash.
Remedy: DRiV will work with distributors to return unsold parts. Dealers will inspect and replace the ball joint as necessary, free of charge. Owner notification letters were mailed on March 17, 2022. Owners may contact DRiV customer service at 1-877-489-6659 or at [email protected].
AIR BAGS:FRONTAL:PASSENGER SIDE:INFLATOR MODULE · 19V741000
2019-10-17 · EA15001
Toyota Motor Engineering & Manufacturing (Toyota) is recalling certain 2010-2016 4Runner, 2003-2006 Tundra, 2003-2013 Corolla, 2009-2010 Corolla Matrix, 2004-2005 RAV4, 2002-2007 Sequoia, 2011-2013 Sienna, 2008-2012 Scion xB, 2008-2009 Lexus IS-F, 2007-2012 Yaris and Lexus ES350, 2010-2017 Lexus GX460, 2002-2010 Lexus SC430, 2006-2012 Lexus IS250 and IS350 and 2010-2015 Lexus IS250C and IS350C vehicles.
These vehicles had their driver or passenger frontal air bag inflators previously replaced under a prior recall using inflators of the same design. The inflators may explode due to propellant degradation occurring after long-term exposure to high absolute humidity, temperature and temperature cycling.
Consequence: An inflator explosion may result in sharp metal fragments striking the driver or other occupants resulting in serious injury or death.
Remedy: Toyota will notify owners. Depending on the vehicle model, dealers will replace the front driver inflator, front passenger airbag inflator, the airbag assembly, or the front passenger airbag sub-assembly and inflator. The recall began November 20, 2019. Owners may contact Toyota customer service at 1-888-270-9371 or Lexus customer service at 1-800-255-3987. Toyota's numbers for this recall are J0A, J0B, and J0C. Lexus' numbers for this recall are JLI, JLJ, and JLK.
AIR BAGS:FRONTAL:PASSENGER SIDE:INFLATOR MODULE · 18V883000
2018-12-12 · EA15001
Toyota Motor Engineering & Manufacturing (Toyota) is recalling certain 2002-2005 Lexus SC and Toyota Sequoia, 2003-2005 Toyota Corolla and Tundra, and 2003-2007 Pontiac Vibe vehicles. These vehicles are equipped with certain air bag inflators assembled as part of the passenger frontal air bag modules used as original equipment or replacement equipment. In the event of a crash necessitating deployment of the passenger frontal air bag, these inflators may explode due to propellant degradation.
Consequence: An inflator explosion may result in sharp metal fragments striking the driver or other occupants resulting in serious injury or death.
Remedy: Toyota will notify the Toyota and Lexus owners. General Motors will notify the Pontiac Vibe owners. Depending on the vehicle
model, dealers will replace the front passenger air bag inflator with an alternate inflator, or replace the air bag assembly that includes an alternate inflator, free of charge. The recall began January 23, 2019. Owners may contact Toyota customer service at 1-888-270-9371, Lexus customer service at 1-800-255-3987 or Pontiac customer service at 1-800-762-2737. Toyota's numbers for these recalls are J0A (Zone A Toyota), J0B (Zone B Toyota), J0C (Zone C Toyota), JLI (Zone A Lexus), JLJ (Zone B Lexus), and JLK (Zone C Lexus). Note: This recall includes vehicles that have had their air bag previously replaced under an earlier air bag campaign.
Southeast Toyota Distributors, LLC (SET) is recalling certain 2005-2011 4Runner, Highlander, Sequoia, and Sienna, 2005-2010 Avalon and Tundra, 2006-2008 Camry Solara, 2006-2010 Highlander hybrid, 2006-2011 Rav4 and Tacoma, 2007-2010 FJ Cruiser, 2007-2011 Camry hybrid, 2009-2010 Venza, 2010-2012 Prius, 1988-1990 and 2005-2010 Camry, and 1989 and 2009-2010 Corolla vehicles equipped with aftermarket accessory seat heaters with a copper strand heating element. The electrical wiring in the seat heaters may be damaged when the seat cushion is compressed.
Consequence: If damaged, the copper strand heating element may short circuit, increasing the risk of a fire.
Remedy: SET will notify owners, and dealers will disconnect the seat heaters, free of charge, and refund the purchase price of the seat heater accessory. The recall began on July 14, 2016. Owners may contact SET customer service at 1-866-405-4226. SET number for this recall is SET16B.
AIR BAGS:SIDE/WINDOW · 16V065000
2016-02-05
Toyota Motor Engineering & Manufacturing (Toyota) is recalling certain model year 2003-2006 Toyota Land Cruiser and Lexus LX470, 2005-2006 Toyota Tundra and Sequoia, 2004-2006 Toyota 4Runner and Lexus GX470 vehicles equipped with side curtain-shield-air bags. The affected vehicles have an air bag control module that may be improperly programmed, causing the side curtain-shield-air bags to deploy inadvertently.
Consequence: If the side curtain-shield-air bags deploy unexpectedly, it can increase the risk of occupant injury.
Remedy: Toyota will notify owners, and dealers will replace the air bag control module with one that has improved programming, free of charge. The recall began on December 1, 2016. Owners may contact Toyota customer service at 1-888-271-9371. Toyota's number for this recall is G0C and GLB.
AIR BAGS · 15V285000
2015-05-13 · EA15001
Toyota Motor Engineering & Manufacturing (Toyota) notified the agency on May 13, 2015 that they are recalling certain model year 2004 Sequoia vehicles manufactured August 18, 2003, to August 19, 2004, and 2003-2004 Tundra vehicles manufactured March 18, 2003, to August 25, 2004. On June 16, 2015, Toyota expanded the recall to include an additional 1,270,468 vehicles, including model year 2002-2003 and 2005-2007 Sequoia, 2005-2006 Tundra, 2003-2007 Corolla, 2003-2007 Corolla Matrix, 2003-2007 Pontiac Vibe and 2002-2007 Lexus SC vehicles. This is to address a safety defect in the passenger side frontal air bag inflator which may produce excessive internal pressure causing the inflator to rupture upon deployment of the air bag. This recall addresses both the passenger side frontal air bags that were originally installed in the vehicles, as well as replacement air bags that may have been installed as replacement service parts. A replacement air bag may have been installed, as one example, if a vehicle had been in a crash necessitating the replacement of the passenger side frontal air bag.
Consequence: In the event of a crash necessitating deployment of the passenger's frontal air bag, the inflator could rupture with metal fragments striking the vehicle occupants potentially resulting in serious injury or death.
Remedy: 2003-2004 Corolla and Corolla Matrix vehicles that are recalled under both 15V-043 and 15V-285 are under a Do Not Drive advisory. Owners of these vehicles are advised not to drive their vehicles until the recall remedy has been completed. Toyota will notify their owners. Pontiac Vibe owners will be notified by GM. Dealers will replace the front passenger air bag. The recall began on July 13, 2015. Toyota owners may contact Toyota customer service at 1-800-331-4331. Pontiac owners may call 1-800-762-2737. NOTE: This recall supersedes recall 14V-312 in its entirety.
AIR BAGS · 15V286000
2015-05-13 · EA15001
Toyota Motor Engineering & Manufacturing (Toyota) notified the agency on May 13, 2015, that they are recalling 2005-2007 Lexus SC, Toyota Corolla, Corolla Matrix, Sequoia, and Pontiac Vibe, and 2005-2006 Toyota Tundra vehicles that were originally sold, or ever registered, in Florida, along the Gulf Coast, Puerto Rico, Hawaii, the U.S. Virgin Islands, Guam, Saipan and American Samoa. On June 16, 2015 Toyota expanded the recall to cover an additional 769,055 vehicles, including certain model year 2002-2004 Lexus SC, Toyota Sequoia, 2003-2004 Toyota Corolla Matrix, Toyota Corolla, Pontiac Vibe, and Toyota Tundra vehicles, as well the vehicles covered by the May 13, 2015 notification in the portions of Georgia, Alabama, Louisiana, Mississippi and Texas that were not previously included. The inflators in the front passenger air bags are susceptible to rupture in the event of a crash necessitating the deployment of the front passenger air bag.
Consequence: In the event of a crash necessitating deployment of the passenger's frontal air bag, the inflator could rupture with metal fragments striking the vehicle occupants potentially resulting in serious injury or death.
Remedy: 2003-2004 Corolla and Corolla Matrix vehicles that are recalled under both 15V-043 and 15V-286 are under a Do Not Drive advisory. Owners of these vehicles are advised not to drive their vehicles until the recall remedy has been completed. Toyota will notify their owners. Pontiac Vibe owners will be notified by GM. Dealers will replace the passenger side front air bag, free of charge. Owners may contact Toyota customer service at 1-800-331-4331. Toyota began the recall on July 13, 2015. Pontiac Vibe owners may contact GM at 1-800-762-2737. GM began the recall on June 29, 2015. NOTE: This recacll supersedes recall 14V-655 in its entirety. For vehicles located in the U.S. states not listed above, please see Toyota recall 15V-285 which covers all other U.S. states.
EQUIPMENT:OTHER:LABELS · 10V035000
2010-02-03
GULF STATES TOYOTA IS RECALLING CERTAIN MODEL YEAR 2005-2010 VEHICLES FOR FAILING TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 110, "TIRE SELECTION AND RIMS." THESE VEHICLES WERE SOLD BETWEEN SEPTEMBER 1, 2005 AND JUNE 2, 2008 WITHOUT THE REQUISITE LOAD CARRYING CAPACITY MODIFICATION LABELS.
Consequence: THIS DOES NOT MEET THE STANDARD REQUIREMENTS.
Remedy: DEALERS WILL MAIL TO CONSUMERS THE CORRECTED LABEL OR THE CUSTOMER WILL HAVE THE OPTION FOR DEALERS TO INSTALL THE LABEL FREE OF CHARGE. DEALERS WILL ALSO CORRECT THE OWNER'S MANUAL. THE SAFETY RECALL BEGAN ON MAY 27, 2010. OWNERS MAY CONTACT GULF STATES TOYOTA AT 713-580-3300.
EQUIPMENT:OTHER:LABELS · 10V036000
2010-02-03
SOUTHEAST TOYOTA IS RECALLING CERTAIN MODEL YEAR 2005-2011 PASSENGER VEHICLES FOR FAILING TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 110, "TIRE SELECTION AND RIMS." THESE VEHICLES WERE SOLD WITHOUT THE REQUISITE LOAD CARRYING CAPACITY MODIFICATION LABELS.
Consequence: A DRIVER MAY OVERLOAD A VEHICLE WHICH MAY INCREASE THE RISK OF A CRASH.
Remedy: DEALERS WILL MAIL TO CONSUMERS THE CORRECTED LABEL OR THE CUSTOMER WILL HAVE THE OPTION FOR DEALERS TO INSTALL THE LABEL FREE OF CHARGE. THE SAFETY RECALL BEGAN ON MAY 27, 2010. OWNERS MAY CONTACT SOUTHEAST TOYOTA AT 1-800-301-6859.
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. THIS MAY CAUSE THE BALL JOINT TO WEAR AND LOOSEN PREMATURELY, WHICH COULD RESULT IN INCREASED STEERING EFFORT, REDUCED VEHICLE SELF-CENTERING, AND NOISE IN THE FRONT SUSPENSION.
Consequence: IN EXTREME CASES, IF THE VEHICLE IS CONTINUOUSLY OPERATED IN THIS CONDITION, THE LOWER BALL JOINT MAY SEPARATE FROM THE KNUCKLE AND COULD CAUSE A LOSS OF VEHICLE CONTROL.
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.
EXTERIOR LIGHTING · 06E049000
2006-05-24
CERTAIN CK MOTORSPORTS COMBINATION HEADLIGHTS, CLEAR CORNER, BUMPER, AND SIDE MARKER LIGHTS SOLD AS REPLACEMENT LAMPS FOR USE ON THE PASSENGER VEHICLES LISTED ABOVE. SOME COMBINATION LAMPS THAT ARE NOT EQUIPPED WITH AMBER SIDE REFLECTORS FAIL TO CONFORM TO FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED EQUIPMENT.
Consequence: WITHOUT THE AMBER REFLECTORS, THE VEHICLE WILL BE POORLY ILLUMINATED, POSSIBLY RESULTING IN A VEHICLE CRASH WITHOUT WARNING.
Remedy: CK MOTORSPORT WILL NOTIFY OWNERS AND REPLACE THE NONCOMPLIANT LAMPS FREE OF CHARGE. THE RECALL BEGAN ON JULY 1, 2006. OWNERS MAY CONTACT CK MOTORSPORT AT 1-909-610-7211.
AIR BAGS:FRONTAL · 05V328000
2005-07-20
CERTAIN PICKUP TRUCKS EQUIPPED WITH AUTOMATIC TRANSMISSIONS AND OPTIONAL FABRIC FRONT CAPTAIN'S CHAIRS FAIL TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 208, 'OCCUPANT CRASH PROTECTION.' THESE VEHICLES WERE BUILT WITH AN INCORRECT FRONT PASSENGER OCCUPANT CLASSIFICATION SYSTEM INDICATOR LIGHT LENS WHICH WILL NOT DISPLAY THE STATUS OF THE FRONT PASSENGER AIR BAG.
Consequence: AS A RESULT, THE VEHICLE OCCUPANTS WILL NOT BE MADE AWARE OF WHETHER OR NOT THE AIR BAG IS ACTIVATED AND READY TO PROTECT THE OCCUPANT AS APPROPRIATE.
Remedy: DEALERS WILL REPLACE THE FRONT PASSENGER OCCUPANT CLASSIFICATION SYSTEM INDICATOR LENS. THE RECALL BEGAN AUGUST 5, 2005. OWNERS MAY CONTACT TOYOTA AT 1-800-331-4331.
AIR BAGS:ON-OFF SWITCH ASSEMBLY · 05V254000
2005-06-02
CERTAIN PICKUP TRUCKS FAIL TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 225, 'CHILD RESTRAINT ANCHORAGE SYSTEMS.' THESE VEHICLES HAVE A MANUAL AIR BAG ON-OFF SWITCH TO DISABLE THE FRONT PASSENGER AIR BAG AND DO NOT HAVE A CHILD RESTRAINT LOWER ANCHORAGE SYSTEM IN THE FRONT PASSENGER SEAT. THIS SPECIFICATION DOES NOT MEET THE STANDARD REQUIREMENTS.
Consequence: THIS STANDARD ESTABLISHES REQUIREMENTS FOR CHILD RESTRAINT ANCHORAGE SYSTEMS TO ENSURE THEIR PROPER LOCATION AND STRENGTH FOR THE EFFECTIVE SECURING OF CHILD RESTRAINTS, TO REDUCE THE LIKELIHOOD OF THE ANCHORAGE SYSTEMS' FAILURE, AND TO INCREASE THE LIKELIHOOD THAT CHILD RESTRAINTS ARE PROPERLY SECURED AND THUS MORE FULLY ACHIEVE THEIR POTENTIAL EFFECTIVENESS IN MOTOR VEHICLES.
Remedy: DEALERS WILL REMOVE THE MANUAL AIR BAG ON-OFF SWITCH, REPLACE THE OWNER'S MANUAL, AND AFFIX A NEW SUN VISOR AIR BAG WARNING LABEL. THE RECALL BEGAN IN EARLY JANUARY 2007. OWNERS MAY CONTACT TOYOTA AT 1-800-331-4331.
ENGINE AND ENGINE COOLING:EXHAUST SYSTEM · 05V123000
2005-03-30
CERTAIN PICKUP TRUCKS EQUIPPED WITH BOTH VEHICLE STABILITY CONTROL (VSC) AND THE TRD DUAL EXHAUST SYSTEMS. THE TRD DUAL EXHAUST SYSTEM MET ALL CLEARANCE SPECIFICATIONS ON MODELS WITHOUT VSC, HOWEVER THE DRIVER'S SIDE EXHAUST LOCATED IN A POSITION WHERE CONTACT BETWEEN A BRAKE LINE FOUND ONLY ON VEHICLES WITH VSC AND THE TRD EXHAUST PIPE MIGHT OCCUR.
Consequence: IN THIS CONDITION, THE EXHAUST PIPE FLANGE MAY RUB AGAINST THE RIGHT REAR BRAKE LINE, WHICH COULD CAUSE BRAKE FLUID LEAKAGE. THIS COULD LEAD TO AN INCREASE OF VEHICLE STOPPING DISTANCE, WHICH COULD RESULT IN A CRASH.
Remedy: DEALERS WILL INSPECT AND, IF SO EQUIPPED, WILL REPLACE THE TRD DUAL EXHAUST SYSTEM FREE OF CHARGE. DURING THIS REPLACEMENT, THE DEALER WILL ALSO INSPECT THE SPECIFIC BRAKE LINE TO ASSURE IT HAS NOT BEEN DAMAGED AND REPLACE IT IF NECESSARY. THE RECALL BEGAN ON MAY 31, 2005. OWNERS SHOULD CONTACT TOYOTA AT 1-800-331-4331.
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