The 2005 Tundra comes up repeatedly for secondary air injection system failure—the pump, switching valves, and check valves. Owners start seeing check engine lights and loss of engine power anywhere from 38,000 to 150,000 miles, with one truck failing at just 4,500 miles. When the pump goes bad, the engine goes into "limp mode," which kills acceleration and makes merging into traffic dangerous. Repair bills run $1,300 to $4,000. Toyota extended the warranty on this exact system for 2007–2010 Tundras due to known defects, but refuses to cover 2005 models with the same parts and same failure. Owners report dealer service managers acknowledge the problem exists across multiple Toyota models.
The electronic throttle control (drive-by-wire) shows a separate problem: nearly a 1-second delay between pressing the gas pedal and engine response, especially from idle or while decelerating. Drivers unknowingly increase throttle input during that delay, then the engine suddenly jumps to that cumulative input, causing violent lurching. One owner—an electronics engineer—identified it as a software issue. Unrelated to that, some owners report excessively high cold idle speed that drops when the engine warms up, and one radiator failure that caused instant coolant loss and engine death. Another truck developed an exhaust manifold leak that let carbon monoxide into the cabin; the dealer and manufacturer refused to address it.
Failure modes owners describe
Secondary Air Injection System (Pump, Switching Valve, Check Valves) Failure
The secondary air injection pump, air switching valves (Bank 1 and Bank 2), and check valves fail prematurely, causing loss of engine power and illumination of the check engine light. In several cases, owners report the valves become stuck closed due to insulation foam clogging and deposits. The secondary air inlet hose also hardens under the intake manifold heat, contributing to cooling issues.
When: 38,000 to 150,000 miles; one case as early as 4,500 miles on a new truck
Symptoms owners cite: Check engine light illumination; Sudden loss of acceleration power and 'limp mode' operation; Engine unable to accelerate to merge with traffic safely; Air leaking from air injection system after starting; Engine failure while driving at highway speeds (65-70 mph); Emission control system failure warning
Codes mentioned: P-1442
Repairs/costs cited: Replacement of secondary air injection pump, air switching valves (both banks), check valves, and secondary air inlet hose. Owners cite repair costs ranging from $1,300 to $4,000, with one dealer quote at $3,745 for pump/valve/driver assemblies and another at $2,158.90 for pump and check valves at 38,000 miles.
Recalls/TSBs owners mention: Toyota extended warranty for air injection pump and air switching valves on 2007-2010 Tundras for 10 years or 150,000 miles from first use. 2005 Tundra owners report Toyota refuses to honor this extension despite having identical systems. Toyota promised reimbursement for future recalls but has not issued a recall for 2005 models. Dealer service manager acknowledged the issue exists on multiple Toyota models including Sienna.
Electronic Throttle Control (Drive-by-Wire) Delay/Unintended Acceleration
The electronic throttle control system exhibits a nearly 1-second delay when accelerating from idle, causing the driver to apply increasing throttle input during the delay period. When the system finally responds, it jumps immediately to the cumulative throttle setting, resulting in sudden lurching acceleration. One owner reported sudden unintended acceleration with brake depressed and accelerator not depressed. An electronics engineer attributed the issue to a software problem.
When: Occurs from idle or during deceleration; one incident reported during lane change in stop-and-go traffic; unintended acceleration incident not specified for timing
Symptoms owners cite: Nearly 1-second delay between depressing gas pedal and engine response; Sudden lurching forward of vehicle when throttle finally responds; Vehicle accelerates quickly when foot removed from brake; Unintended acceleration with brake depressed and accelerator pedal not depressed; Dangerous behavior during stop-and-go traffic and lane changes
Repairs/costs cited: No repair documented in narratives. Owner reports changing driving style to compensate for defect.
Recalls/TSBs owners mention: Toyota dealer service manager acknowledged awareness of the issue on Tundra and stated it is worse on Sienna. No recall or technical service bulletin mentioned.
High Cold Idle Speed
Engine idles at abnormally high RPM when cold-started, approximately twice normal idle speed. Problem disappears once engine reaches operating temperature. Dealer informed owner this is normal behavior.
When: Occurs immediately after cold start; resolves when engine is hot
Symptoms owners cite: Excessively high idle speed when engine is cold; Vehicle accelerates quickly when removing foot from brake or shifting into gear; Problem resolves when engine reaches operating temperature
Recalls/TSBs owners mention: Dealer stated this is normal behavior.
Radiator Failure and Coolant Loss
Radiator develops a seam leak and blows out the bottom, causing instantaneous loss of coolant fluid. In another case, coolant leaks from the overflow reservoir; the radiator cap gasket was found torn.
When: One incident occurred in June 2009 (vehicle year 2005); timing not specified for second case
Symptoms owners cite: Instantaneous loss of engine coolant; Coolant leaking from overflow reservoir; Engine failure due to coolant loss; Coolant extremely dark brown in color (second case); Visible liquid on ground beneath engine
Repairs/costs cited: First case: coolant loss resulted in engine failure; no repair documented. Second case: coolant flush, coolant temperature sensor replacement, and radiator cap replacement (torn gasket).
Leaking Exhaust Manifold
Exhaust manifold develops a leak allowing carbon monoxide to enter the cabin. Carbon monoxide detector activated while driving. Manufacturer and dealer refuse to repair.
When: Not specified
Symptoms owners cite: Carbon monoxide detected in cabin; CO detector triggered while vehicle in use; Visible exhaust manifold leak
Recalls/TSBs owners mention: Dealer and manufacturer refuse to repair the leaking exhaust manifold.
Synthesized from 19 NHTSA owner complaints — unverified consumer
allegations, summarized for patterns. The verbatim filings appear below.