2025 Toyota Tacoma

Vehicle Cannot Be Safely Driven – Structural / Suspension Defect Suspected – Dealer Claims “Repair Completed” Despite Unequal Wheelbase My vehicle is currently unsafe to operate, due to the following critical issues: ⸻ 1. Left–right wheelbase inconsistency The front and rear wheelbase measurements are not equal side-to-side. This is a strong indicator of structural deviation, such as: •Subframe misalignment •Control arm mounting point displacement •Deformed suspension components •Manufacturing or assembly error in chassis geometry ⸻ 2. Front caster angles remain abnormal •Left caster: 3.9° •Right caster: 4.9° •Cross-caster difference: 1.0° A 1° difference exceeds manufacturer tolerances and causes: •Vehicle drifting •Poor straight-line stability •Uneven steering return •Potential instability during emergency braking This is a safety-related steering geometry defect. ⸻ 3. Real-world driving confirms unsafe behavior The vehicle cannot maintain straight-line travel, the steering wheel is off-center, and the car exhibits instability at normal speeds. This makes the vehicle unsafe to drive. ⸻ 4. Despite these unresolved issues, the dealership insists the vehicle is “repaired” and demands that I pick it up. They refused to provide frame measurement reports or explanation for the unequal wheelbase. Returning a vehicle with unresolved steering and chassis geometry defects constitutes unsafe vehicle delivery. ⸻ Conclusion Based on unequal wheelbase, abnormal caster geometry, and inability to drive safely, this vehicle likely contains a structural or assembly defect. I formally request investigation, suspension geometry verification, and required action from the manufacturer, as this is a matter of public road safety.

I was driving to work when after running across a minor pothole I heard a clunking sound. It turns out it's the top cap for the front coil-over Bilstein shocks had broken allowing the shaft and the bump stop to protrude through the upper mounting plate. The coil did its job of keeping the vehicle suspended, but the shock piston has no ability to alleviate any stresses put upon the coil. Dealer states that because there was an outside contribution, i.e. a pothole, which had been driven around and over many times before, wasn't warrantable. There was no more than standard bump and sway than when driving around as usual. There was no shudder as though I was going too fast for the defect in the road. I dont know if there was pre existing stress damage from a recent collision(opposite corner of truck) or if the was a defect with the part. The top cap is made out of aluminum rather than steel, which I find disturbing after learning this is not the first to have broken. This vehicle has only been off pavement in gravel driveways and parking lots. I hope you can investigate this thoroughly.

The vehicle was being operated in 4-wheel-drive, mode 4H, and when turning to the left at low speed, there was a grinding noise from the front of the vehicle and it would not proceed. The vehicle had to be put back in 2-wheel-drive, mode 2H, put in reverse, backed up a short distance, and then put back in drive, and then it was able to proceed. This is likely the CV joint issue reported in other 2024 and 2025 Toyota Tacomas. The dealer has been notified, and the vehicle will be taken in for service.

While driving on a dry, clearly marked two-lane highway in Montana, I had Lane Tracing Assist and Active Lane Keep/Track Assist turned on. My hands were on the steering wheel, speed was within the limit, and visibility was clear. The truck unexpectedly steered itself out of the lane toward the right-side guard rail. There were no audible or visual lane-departure alerts, no “steering assist canceled” message, and the Pre-Collision System did not apply braking before impact. The vehicle struck the guard rail. The system failed on multiple safety layers — no lane warning, no steering correction, and no automatic braking — under normal conditions (dry pavement, well-painted lane lines, daylight). I believe this represents a malfunction or defect in the driver-assist software or sensor calibration for Toyota Safety Sense 3.0. I request NHTSA investigate similar incidents for 2024–2025 Toyota Tacoma models equipped with LTA/LDA and Pre-Collision System to determine whether a systemic defect exists.

The door handle mechanism which is made of plastic broke on the inside of the door. It was the piece the cable connects to which pulls to release the door latch for opening. Only way to get out of door is to roll window down and open from outside the vehicle. Truck has 7k miles currently and no heavy use. Under proper circumstances this could be very dangerous.

My 2025 Toyota Tacoma SR5 has an ongoing issue where Apple CarPlay frequently disconnects or fails to connect altogether. This happens both at startup and randomly while driving. The problem occurs across multiple iPhones, different cables, and even after ensuring that both the phone and the truck’s software are updated. Many other 4th-generation Tacoma owners (2024–2025) are reporting the same issue online — CarPlay will drop connection, the system freezes, or CarPlay will not appear as an available input for long periods. Because CarPlay is a key part of the hands-free system for navigation, calls, and messaging, these disconnections cause drivers to interact manually with their phones, which creates a potential safety hazard. Toyota dealerships acknowledge the problem but currently have no permanent fix. It appears to be a system-wide defect in the Audio Multimedia 6.0 system used in the new Tacomas. I’m submitting this report so NHTSA can investigate and, if appropriate, prompt Toyota to issue a software or hardware recall to address the defect.

•What component or system failed or malfunctioned, and is it available for inspection upon request? I purchased a 2025 Toyota Tacoma from Carver Toyota of Columbus, IN, 47280 brand new with only 15 miles. I also purchased the 100,000-mile bumper to bumper warranty that covers third party parts. After driving the vehicle for 5,000 miles, I noticed problems with Transmission or the Powertrain System whenever I would shift from 2nd to 3rd gear, down shift, shift to reverse, and would slip acceleration whenever the vehicle is sitting idle. •How was your safety or the safety of others put at risk? This has impacted my safety and the safety of others by not properly shifting into gear. When accelerating it engages harshly from 2nd to 3rd gear. I can’t properly accelerate whenever the vehicle is idle; thus causing safety concerns when operating this vehicle. •Has the problem been reproduced or confirmed by a dealer or independent service center? Yes, on [XXX], I took the vehicle into to Carver Toyota Service Center with only 10,639. My warranty covers 100,000 miles bumper to bumper. •Has the vehicle or component been inspected by the manufacturer, police, insurance representatives or others? The Service Member with Carver Toyota “test drove” and confirmed that the vehicle shifted harshly from park to reverse and from 2nd to 3rd gear. The vehicle fluids were checked and were found to be low. The fluids were “topped off” and the vehicle was returned back to me within one day of my delivering it to them. •Were there any warning lamps, messages or other symptoms of the problem prior to the failure, and when did they first appear? At the time of my reporting this issue with Carver, there were no warnings or error codes indicted by the vehicle. However, this is a well known issue with this make and model of the Toyota Tacoma. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)