Toyota Recalls Tacoma TRD Off-Road Models after a corrosion problem with Bilstein dampers threatens the integrity of the suspension system.
Scope of the recall and affected vehicles
The National Highway Traffic Safety Administration (NHTSA) records show that 48,280 trucks built for the 2024 and 2025 model years are included. Not every unit was sold in the United States, but all covered vehicles share the same off‑road suspension package.
The standard equipment on these trucks includes a Bilstein shock absorber with an external oil reservoir. A welded flange that joins the reservoir to the shock body may corrode, creating a weak point where the metal can separate.
When the connection fails, the reservoir can detach and fall off while the vehicle is in motion. That situation could generate a road hazard, potentially leading to loss of control or injury.
How the problem was discovered
The automaker first learned of the defect in September 2025 after two owners reported leaking shocks. A dealer inspection confirmed that one of the reservoirs was missing, prompting a broader investigation.
Analysis of a supplier teardown identified an untreated metal area between the reservoir, flange and damper body. Exposure to salt spray and rock debris appears to accelerate the corrosion, especially on flanges of a certain length.
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By the end of July, the company had logged 20 field technical reports and 62 warranty claims related to the issue.
Dealers received notification earlier this month and will begin inspections. The front and rear assemblies will be swapped out at no cost, using revised parts that address the corrosion risk.
The recall notice will be mailed to owners by October 5, 2026.
For additional details, the NHTSA recall page provides official documentation.
The Bilstein dampers fitted to the TRD Off‑Road variant are designed with an external oil reservoir that sits outside the main shock body.
In the affected trucks, the weld that secures the reservoir is positioned where the metal transitions from the reservoir flange to the damper cylinder. Because this junction is not protected by a corrosion‑inhibiting coating, it is directly exposed to the elements. When the vehicle operates in regions that experience heavy winter de‑icing or frequent encounters with salty road treatments, the metal surface accelerates its oxidation. Similarly, off‑road excursions that kick up stone fragments can abrade protective layers and introduce moisture, further promoting rust formation at the vulnerable spot.
