A potentially serious issue has been identified in certain 2024-2025 Toyota Tacoma 4-wheel drive trucks, prompting a safety recall by the manufacturer. The problem involves dirt buildup inside the rear wheels of affected vehicles, which can cause damage to the rear brake hoses and potentially lead to brake fluid leaks.
The issue affects Toyota Tacoma trucks equipped with 16-inch brake systems and 17-inch wheels, where the brake hoses are attached to the rear brake calipers and transfer brake fluid under hydraulic pressure. The clearance between the brake hoses and wheels in these vehicles is smaller than in other combinations, making them more susceptible to damage from mud and dirt buildup.
When operating in off-road conditions, mud and dirt can accumulate on the interior of the rear wheels and come into contact with the brake hoses. Over time, this can cause wear and tear on the hoses, leading to damage and potentially resulting in a brake fluid leak. A brake fluid leak can reduce brake performance and increase stopping distances, significantly increasing the risk of a crash.
The problem was first reported by dealers in mid-July 2024, with several instances of rear brake hose leaks observed in 2024 Toyota Tacoma vehicles with the affected wheel and brake combination. Upon further inspection, dealer technicians found that the rear brake hoses were damaged and worn through, and that mud and dirt buildup on the inside of the rear wheels was causing the hoses to rub against the debris.
Toyota’s investigation into the issue revealed that the manufacturing processes used to install the brake hose were following proper routing procedures. However, a design review of the rear brake system found that the clearance between the brake hose and wheel in affected vehicles was smaller than in other combinations. Additionally, the positioning of the rear brake hose on 16-inch brakes was different and outside of the rear caliper profile.
Based on the results of its investigation, Toyota concluded that 4-wheel drive vehicles with 16-inch rear brakes and 17-inch Toyota wheels may experience rear brake hose damage due to mud and dirt buildup on the interior of the wheels. The company has decided to conduct a safety recall to address the issue. As of January 29, 2025, Toyota has received five field technical reports and twelve warranty claims related to this condition in affected vehicles.
To correct the problem, dealers will replace both rear brake hoses in affected vehicles. Interim letters notifying owners of the safety risk are expected to be mailed on March 24, 2025, with a second letter to follow once the remedy is available. Toyota’s recall numbers for this campaign are 25TB04 and 25TA04, and the NHTSA campaign number is 25V-058.
The National Highway Traffic Safety Administration (NHTSA) Office of Defects Investigation (ODI) is continuing to investigate certain Ford Fusion and Lincoln MKZ sedans for front brake hoses that could prematurely rupture.
