Toyota Recalls 48,280 Tacomas Over Detaching Bilstein Damper Reservoirs

Quick Summary:

• The Issue: Untreated weld surfaces on the external reservoir flanges of Bilstein dampers can corrode, crack, and cause the reservoir to detach completely.
• Vehicles Impacted: Exactly 48,280 total 2024–2025 Tacoma TRD Off-Road trucks (43,827 gas models and 4,453 hybrids, with only 2 units from the 2025 model year).
• The Fix & Timeline: Remedy notifications are scheduled to go out between Sept. 21 and Oct. 5 for replacement dampers.
• What to Do: Check your VIN on Toyota's or NHTSA's recall portals and limit driving if your dampers are affected until repairs are completed.

If you’re an old-school Toyota pickup owner, rust is always a concern. Unfortunately, rust (or corrosion, at the very least) is once again at the heart of a recall for 48,280 2024–2025 Tacomas. The issue stems from a failure of the flange holding the external reservoir of its Bilstein dampers, which allows the reservoir to fall off. This defect creates a road hazard and could lead to issues with the remaining damper body.

Which 2024–2025 Toyota Tacomas Are Impacted?

Key Facts: Limited to TRD Off-Road trims | 43,827 gas-only models affected | 4,453 are hybrids

Toyota confirmed these dampers are equipped on 2024 Tacoma TRD Off-Road models with the optional i-Force Max hybrid engine and 2024–2025 Tacoma TRD Off-Road models with the standard 2.4-liter turbocharged I-4 engine. Toyota stresses that the 2025 model year Tacoma TRD Off-Road represents “a very small number” of the affected trucks; documentation lists just 2 units.

Model year 2026 TRD Off-Road trucks are not part of this recall. We reached out to Toyota to clarify what changes were made between the 2026 parts and the replacement dampers for the 2024–2025 versions. A Toyota representative was only able to confirm to Carbage that an improved damper assembly was implemented by Dec. 2024 and could explain why only two 2025 model year TRD Off-Road models are included in this recall.

How Are the Flanges Failing?

According to the Part 573 safety recall report, the lower weld surfaces of the flange holding the external reservoir to the Bilstein damper are untreated, allowing corrosion to occur. Combined with the length of the flange, the expanding corrosion creates enough pressure to cause a crack. This eventually causes the flange to fail and the reservoir to detach.

According to that same report, Bilstein recommended a production update to install a “shorter flange” on those assemblies between January and April of this year.

What to Look Out For

Key Facts: These Bilstein dampers have red bodies | Part numbers included below

Toyota provided part numbers for the affected dampers: 48510-AK042 and 48510-AK032 for the front, and 48530-AK030 and 48530-AK020 for the rear. Both sides share the same part number because each side is interchangeable. The difference in part numbers distinguishes the hybrid version from the standard gas version. These OEM dampers feature red bodies instead of Bilstein’s traditional aftermarket clear-anodized aluminum finish. Toyota stated technicians will inspect for a “certain length,” though the public documentation does not specify that exact measurement.

Is There a Fix?

The recall report indicates a replacement Bilstein damper exists, but it is either in development or in the process of being stocked; remedy notifications will go out between Sept. 21 and Oct. 5. A Toyota spokesperson confirmed to Carbage that the recommended shorter flanges will be used on these replacement dampers.

You can check whether your truck is affected by running its VIN through Toyota’s recall portal or the NHTSA website. Doing so allows you to confirm whether your Tacoma TRD Off-Road requires replacement dampers. If it does, limiting your driving until technicians install the updated parts may be wise.

Upgrading using used OEM parts is a popular way to make a standard Toyota Tacoma a much better off-roader without spending large amounts of cash on aftermarket parts. But this recall shows why going this route has its risks. Be wary of any TRD Bilstein dampers with welded external reservoir flanges sold on eBay or online marketplaces. These could easily be parts affected by the recall, putting your truck at risk with repairs not covered under this recall or worse. If you spot a secondhand set, ask for the donor vehicle's VIN or model year, and proceed with extreme caution. If you are able to get the donor’s VIN, run it though the recall checker to make sure those dampers aren’t under the recall.

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