TSB: REVISION NOTICE July 01, 2019 Rev2: ? Applicability has been updated to 2019 ? 2020 model year Toyota vehicles. ? The Techstream Preparation and Process Overview sections have been updated. October 30, 2017 Rev1: ? Applicability has been updated to include 2018 model year vehicles. Any previous printed versions of this bulletin should be discarded. SUPERSESSION NOTICE The information contained in this bulletin supersedes SB No. T-SB-0012-13. Service Bulletin No. T-SB-0012-13 is obsolete and any printed versions should be discarded. Be sure to review the entire content of this bulletin before proceeding. Flash reprogramming allows the Electronic Control Unit (ECU) software to be updated
full bulletin at NHTSA ↗2005 Toyota Tundra electrical problems
severe 11 complaints filed with NHTSA · avg repair $850 · see electrical across all vehicles →
Failure mileage
Complaints
11
Recalls
0
Avg fix
$850
1crash
2fires
1injury
When does it fail?
Of the 11 electrical complaints filed for the 2005 Toyota Tundra, here's the actual mileage breakdown — failures cluster heaviest at 50,000-75,000 mi.
0-25k
25-50k
50-75k
75-100k
100-125k
125-150k
150k+
Each bar shows the share of total complaints filed at that mileage range. Peak failure window highlighted. Some owners report problems earlier; some make it well past 150,000 miles symptom-free. Maintenance habits and driving conditions shift the curve as much as mileage alone.
What stands out
No new NHTSA electrical complaint has been filed on this vehicle in over 11 years — the issue may be aging out of the active population.
Is there a fix? Manufacturer service bulletins
The manufacturer has issued service bulletins covering electrical on this vehicle — documented repair instructions, service campaigns, or warranty extensions sent to dealers. A TSB isn't a recall (it's not a free safety remedy), but it's the manufacturer acknowledging the issue and how to fix it.
TSB: REVISION NOTICE November 22, 2017 Rev1: ? Applicability has been updated to include 2014 ? 2018 model year vehicles. Any previous printed versions of this bulletin should be discarded. In the event that a Toyota vehicle becomes submerged in water, many components may be physically damaged. Electrical and electronic components, including wiring harnesses, are particularly susceptible to corrosion and subsequent malfunction. Although any flooding can be damaging, salt water flooding elevates the potential for abnormal conditions and may increase risks due to its highly corrosive and conductive nature. Salt residue also continues to corrode and remain conductive even after a vehicle dries.
full bulletin at NHTSA ↗TSB: SUPERSESSION NOTICE The information contained in this bulletin supersedes SB No. T-SB-0101-11. Applicability has been updated to include 2016 ? 2017 model year vehicles. Service Bulletin No. T-SB-0101-11 is Obsolete and any printed versions should be discarded. Be sure to review the entire content of this bulletin before proceeding. When servicing interior electrical switches and components, please note the precautions in this bulletin to avoid damaging electrical components and switches. Many lubricants, cleaners, and automotive chemicals contain silicone or other compounds that may contaminate electrical contacts, and therefore increase electrical resistance and decrease switch perfor
full bulletin at NHTSA ↗TSB: OBSOLETE NOTICE: September 14, 2016: This bulletin is now obsolete. Please see T-SB-0134-16.
full bulletin at NHTSA ↗TSB: Supersession Notice. Flash reprogramming allows the ECU software to be updated without replacing the ECU. Flash calibration updates for specific vehicle models/ECUs are released as field-fix procedures described in individual Service Bulletins. This bulletin details the Techstream ECU flash reprogramming process and outlines use of the Technical Information System (TIS) and the Calibration Update Wizard (CUW). Flash calibration updates can only be applied to the vehicle/ECU combination for which they are intended. ECUs have internal security that will not allow them to be programmed with another ECU?s information.
full bulletin at NHTSA ↗Source: NHTSA manufacturer communications. Bring the bulletin number to your dealer or shop.
The failure pattern owners describe
The 2005 Tundra's electrical system shows multiple, serious failure patterns across this complaint cluster. The most common issue is air injection pump and secondary air switching valve failure, striking owners between 80,000 and 121,000 miles. Toyota issued a warranty extension (10 years/150,000 miles) for this defect on 2007–2010 models but explicitly excluded the 2005, despite it having identical parts. Owners report repair costs of $3,000–$4,000 and dangerous limp-mode activation on the highway. Toyota offered only 50% reimbursement to 2005 owners.
Secondary failure involves a corroded 15-pin transmission connector on the driver side, causing sudden power loss and bucking around 80,000 miles; parts remain backordered nationwide. One owner reported engine stalling during normal driving followed by a failed restart; the dealer's ignition fuse replacement didn't hold—the engine shut off again within a block.
Parasitic electrical drain is documented: one owner's driver-side power window rolls down involuntarily hours after parking and locking the vehicle, and the alarm activates without cause. The dealer could not diagnose or repair it. One truck caught fire at the engine compartment floor around 100,000 miles, destroying the vehicle. A reported unintended acceleration incident at an intersection resulted in a crash and serious injury. Lastly, a lens casing melted from excessive heat near the rear sliding window.
Same Toyota Tundra electrical reports on nearby years: 2006 · 2007 · 2008
Failure modes owners describe
Power window and alarm malfunction
Driver's side power window rolls down on its own after vehicle is locked and parked, sometimes hours later. Alarm also activates spontaneously with no one near the truck. Toyota dealer unable to diagnose or repair. Owner forced to disconnect battery manually after each use as temporary workaround.
When: Started at 50,000 miles; ongoing through 79,900 miles
Symptoms owners cite: Power driver's window rolls down involuntarily after ignition off and vehicle locked; Sporadic alarm activation with no external trigger; No pattern; can occur between 2 minutes to many hours after parking
Repairs/costs cited: Local Toyota dealer unable to identify cause or provide repair; owner's temporary workaround is manual negative battery cable disconnection
Air injection pump and secondary air switching valve failure
Pump and air switching valves malfunction, triggering check engine light and causing limp mode on highway (dangerous condition). Toyota issued warranty extension to 10 years/150,000 miles for 2007–2010 Tundra and 2008–2010 Sequoia models but excluded 2005 Tundra despite having identical parts. Multiple owners report same defect; repair costs $3,000–$4,000. Toyota offered only 50% cost reimbursement on 2005 models.
When: Reported on vehicles with 80,000–121,000 miles; within 10-year window of first use
Symptoms owners cite: Check engine light (P1445 code); Limp mode activated on highway; Secondary air injection system valve stuck closed
Codes mentioned: P1445
Repairs/costs cited: Air injection pump and air switching valve replacement; multiple owners cite $3,000–$4,000 repair cost
Recalls/TSBs owners mention: Toyota issued warranty extension (ZTQ) for 2007–2010 Tundra and 2008–2010 Sequoia (10 years/150,000 miles) but refused to extend same coverage to 2005 Tundra; offered 50% reimbursement only
Transmission connector corrosion and power loss
Corroded 15-pin connector on driver side of transmission causes sudden loss of power and bucking on highway. Multiple owners report same failure around 80,000 miles. Nationwide backorder reported for replacement part.
When: Around 80,000 miles
Symptoms owners cite: Sudden loss of power on highway; Vehicle bucking; Requires towing
Repairs/costs cited: Corroded 15-pin transmission connector replacement; nationwide backorder on part
Engine stalling and ignition fuse failure
Engine shuts off while driving (during left turn); radio and lights remain operational but engine will not restart. Toyota dealer replaced ignition fuse, but engine shut off again immediately upon leaving dealership parking lot. Recurring failure.
When: Mileage not specified
Symptoms owners cite: Engine shuts off while driving; Radio continues to operate; Headlights and horn work; Engine will not restart despite battery replacement; Recurrence after dealer repair
Repairs/costs cited: Toyota dealer replaced blown ignition fuse; problem recurred within one block
Engine compartment fire
Burning wire fumes and fire originating from front driver's side floor. Vehicle completely destroyed. Heat from fire prevented hood from being opened for immediate inspection. Owner escaped without injury but vehicle was total loss.
When: Approximately 100,000 miles
Symptoms owners cite: Burning wire odor from front of vehicle; Fire on engine compartment floor (driver side); Extreme heat preventing hood access; Total vehicle destruction
Repairs/costs cited: Vehicle destroyed; manufacturer to conduct further inspection and diagnosis
Recalls/TSBs owners mention: Manufacturer notified of failure and scheduled further inspection
Unintended acceleration
Engine accelerated to approximately 50 mph despite full brake application while proceeding through intersection. Driver unable to brake despite hard pedal application. V8 engine power overcame braking. Vehicle struck oak tree 150–200 feet from intersection and was totaled.
When: 01/04/2011; mileage not specified
Symptoms owners cite: Sudden unintended acceleration; Brakes applied hard but ineffective; Engine accelerates despite brake pressure
Repairs/costs cited: Vehicle totaled by insurance; driver sustained broken left arm requiring surgery
Lens casing burn damage
Holes burned into lens casing located above sliding glass window to rear of driver. Excessive heat from bulbs or nearby material caused damage.
When: Mileage not specified
Symptoms owners cite: Burned holes in lens casing
Repairs/costs cited: Lens casing damage from excessive heat
Synthesized from 11 NHTSA owner complaints — unverified consumer allegations, summarized for patterns. The verbatim filings appear below.
What owners are reporting 2 most recent
Toyota has extended its warranty for the air injection pump and air switching valves on 2007-2010 tundras. The extension is for 10 years or 150,000 miles from first use. I have a 2005 tundra that has a failing air injection system. I am within 10 years of first use. The truck has the same air injection system as the tundras within the warranty extension, but Toyota refuses to honor the…
Secondary air switch stuck open... Loss of power that could have been serious in certain situations. *tr
Had electrical trouble with your 2005 Toyota Tundra?
File a complaint with NHTSA → It's free, official, and how every report above got here — owner filings are the federal safety record this page is built on.
Common questions
How serious is the electrical problem on the 2005 Toyota Tundra?
It's a meaningful issue. 11 complaints have been filed and the failure mode causes operational problems for owners. Repairs average $850.
At what mileage does the electrical typically fail?
Across the 10 complaints that reported odometer mileage, most electrical failures cluster between 50,000 and 100,000 miles, with the median around 81,000. A quarter of owners report trouble before 50,000; a quarter make it past 100,000. Maintenance history matters more than the odometer alone — this is the reported failure window, not a guarantee.
What does it cost to fix?
Independent shops typically charge around $850 for electrical repairs on this vehicle. Dealer pricing tends to run 20-40% higher. The exact figure depends on the specific failure mode, parts availability, and your local labor rates. If you're outside factory warranty, an extended service contract often covers this category.
Are there any recalls related to electrical?
No active recalls currently cover electrical issues on this vehicle. The complaints filed represent owner-reported failures that haven't risen to the level of a manufacturer-issued recall — but they're still worth knowing about before you buy or budget for repairs.
Related
Complaint and recall data sourced from the National Highway Traffic Safety Administration (NHTSA)
public records database. Verify the raw federal record at
nhtsa.gov/vehicle/2005/Toyota/Tundra.
Severity ratings are derived from reported crashes, fires, injuries, and fatalities. Repair cost estimates are
independent-shop national averages and may differ in your area. Some links on this page are affiliate links.