Toyota Tundra 1st Generation (XK30/XK40) 2000-2006 Review

The Tundra received a facelift for the 2003 model year, but the changes weren't too major. The 1st-gen Toyota Tundra XK30 and XK40 are the pre-facelift and facelifted models' codes, respectively. 2003 wasn't the only facelift and there were various other updates over the years. 2004 and 2005 also saw changs. Here they all are:

The old, enclosed grille is replaced with a larger body-colored one that is open at the bottom, all the way to the bumper, and now has two main bars instead of the old version's center bar and additional fussy slats¹. The grille bars are repeated in the bumper, more noticeable on models with chrome grilles. The bumper is also new, with a revised lower air intake² and new round foglights to replace the old rectangular ones³.

The Tundra gets new headlights with an additional round lens in the inside lower corner and new twin-pod outer amber lenses for the side markers and turn signals on some of the trims¹.

The rear remains unchanged.

The Tundra gets redesigned taillights¹ with a clear top section containing the backup lights and turn signals. The sheet metal of the tailgate is smoothed out, losing the horizontal crease that ran through the release handle. The tailgate now has a subtle curve at the top and is no longer flat².

The side is broadly similar, save for new wheel designs¹ and revised wheel-arch moldings². The new front bumper can be seen from the side as well³. On the Access Cab, the protective side moldings no longer extend to the bed's sheet metal⁴ and the revised fuel flap loses its keyhole and gains a lift tab⁵.

The new combination taillights can clearly be seen in the side view¹, as well as the subtly revised side-marker lights and door-protection strip on some trims².

In 2003, minor interior updates are made. The gauge cluster is tweaked and main dials are updated; the auxiliary gauges change from oval to semi-circular. The new center console is similar to the one in the Sequoia SUV. There are more revisions made in 2005, with round gauge cluster for this model year.

At launch, the 1st-gen Tundra was offered with a base 3.4-liter V6 engine with a choice of a five-speed manual or four-speed automatic transmission, and either 2WD or 4WD. The only other engine choice was a 4.7-liter V8, only available with 4WD and the automatic transmission. Everything changes for the 2005 model year when the 3.4-liter V6 was retired in favor of a new 4.0-liter V6, the 4.7 V8 received a power boost, the five-speed manual transmission on the V6 was replaced by a six-speed unit, and the old four-speed automatic transmission was retired in favor of a new five-speed unit. At the same time, all V6 4WD versions are dropped. The status quo remained unchanged for the last two model years.

The best fuel economy in the lineup is produced by the 4.0-liter V6 with the five-speed automatic transmission, which can deliver an EPA-estimated 18 mpg on the combined cycle - this is good for a range of 475 miles, thanks to a gas-tank capacity of 26.4 gallons. Owners generally improve upon the EPA's estimate in real life although it seems that many of the submitted results were obtained during highway driving and the EPA's combined estimate remains a more accurate overall figure.

* Real-world mpg and MPGe figures are provided by the EPA. Once a car has been on sale for a significant period of time, the EPA gets real-world figures directly from the customer base. These figures are then provided on the EPA website. Real-world figures are not available for certain models due to a lack of sales, or not enough people partaking in this after-sales survey.

Safety features were in short supply in the early 2000s, and the base Tundra has only two front airbags as standard. ABS was optionally available on all models and came bundled with daytime running lights. ABS brakes become standard equipment for the 2003 model year. In 2004, stability control becomes optionally available for Double Cabs and, in 2005, side airbags for the front seats and full-length curtain airbags become available as an optional extra on Double Cabs and the availability of the optional stability control is expanded to all models in the range.

The Tundra starts out with mediocre NHTSA crash scores, but these improved over the years and the 2005+ Double Cab with the optional front side and curtain airbags is the most desirable and the safest Tundra in a crash.

The Tundra kicked off with Base and SR5 trims in 2000, with the Limited package, which is usually regarded as a trim, added in 2001. Engine and drivetrain availability differ per trim and vary over the years. The Regular Cab comes with the long bed only, and the Access Cab with its rear-opening rear doors only with the short bed. The StepSide bed becomes available on the Access Cab body from 2003, and an extended-wheelbase four-door Double Cab is launched in 2004. Standard and optional luxury and safety features and are added through the years.

There were a few special editions too:

• 2003 T3 Special Edition. The Terminator 3 movie prompted the release of the Tundra T3 Special Edition. It comes as standard with T3 badging, a TRD performance package, blacked-out exterior trim, and model-specific 17-inch alloy wheels and interior trim. Only 850 were made - 650 2WDs for the US and 200 4WDs for Canada.
• 2006 Darrell Waltrip Edition. Built to honor the NASCAR driver Darrell Waltrip's participation in the NASCAR Truck Series, this special edition is based on the V8 Double Cab. It includes various special touches, unique badging, and model-specific 18-inch alloy wheels. 2,000 examples were produced.
• 2006 TRD Yamaha Special Edition. This bespoke limited V8 edition built in conjunction with Yamaha had various styling alternations, special 17-inch wheels, and dual exhaust, but was sadly the preserve of our northern neighbor, having been sold in Canada exclusively.

Here are the most notable annual changes to the Tundra range:

2001:

• Arrival of the Limited package/trim
• Arrival of the TRD Off-Road package

2002:

• A limited-slip differential becomes available on the V8 engine

2003:

• A facelift is applied to the lineup
• V8-only Access Cab StepSide becomes available in SR5 and Limited trims
• Sport-tuned suspension system becomes available
• ABS brakes become standard equipment
• The Tundra inherits the Sequoia SUV's center console

2004:

• Four-door extended-wheelbase Double Cab body style is launched in Limited trim
• Stability control becomes optionally available on Double Cabs

2005:

• New headlights and taillights
• Base 190-hp 3.4-liter V6 replaced by 245-hp 4.0-liter V6
• 4.7-liter V8 uprated from 245 hp to 282 hp
• Four-speed automatic transmission is replaced with five-speed automatic
• Five-speed manual transmission is replaced with six-speed manual
• Front bench seat is made available on Double Cab to provide six-seater option
• Optional front side and full-length curtain airbags are available on the Double Cab

2006:

• Engines remain unchanged but outputs are re-rated according to latest SAE standards

Here is the trim lineup:

The interior sets no new standards and, even though the materials used are tough and hardy, it is not as upmarket as some other Toyotas. Still, it is ergonomically sound and in terms of refinement and isolation, it rivals many sedans at the time. Not being a proper full-size truck becomes evident in the restricted cabin width, which is less than full-size domestic rivals. The Access Cab is also rather cramped in the back with only 28.6 inches of legroom, significantly less than its contemporary F-150 SuperCab's 32.7 inches. The Double Cab with its extended 104.5-inch wheelbase has a lot of space, lengthwise, with its 37.5 inches of rear legroom coming very close to full-size domestic rivals - the F-150 SuperCrew offers only a little bit more at 39 inches. However, passengers will still be rubbing shoulders due to the narrower cabin; rear shoulder room is down a full 3.6 inches from the Ford.

While the lube service happens typically every 5,000 miles, more items are checked every 15,000 miles, with this service costing around $415 at Toyota and $230 at an independent shop for the 3.4 V6, $390 or $200 on the 4.0 V6, and $405 or $220 on the 4.7 V8.

30,000-mile services call for the coolant, air filter, cabin filter, and spark plugs to be replaced as well, taking this service to around $1,180 or $840, respectively, on the 3.4 V6, $1,400 or $1,050 on the 4.0 V6, and $1,140 or $815 on the 4.7 V8. Replace the fluid of the automatic transmissions at least every 60,000 miles. This probably won't cost much more than $300. The 90,000-mile cambelt-replacement service is the most expensive one, costing $2,520 or $2,000 on the 3.4 V6 and $2,700 or $2,110 on the 4.7 V8. The 4.0 V6 has a cam chain that only has to be replaced when it starts to rattle.

The Tundra's engine oil and oil filter should be replaced every 5,000 miles. If you're going to buy the oil and filter and do the lube service yourself, the oil capacity of the 3.4 V6 is 5.5 quarts, the 4.0 V6 is 4.8 quarts, and the 4.7 V8 is 6.6 quarts. You'll pay between $63 and $83 for the oil and filter, depending on the engine. Having this service performed at Toyota should set you back about $280, or around $145 at an independent workshop on the 3.4 V6, rising to $320 or $150 on the 4.0 V6 and $335 or $165 on the 4.7 V8. The engine air filter costs between $25 and $31, depending on the engine, and a set of six spark plugs costs between $19 and $23 on the V6s; eight spark plugs cost a significantly more expensive $83 on the V8.

Here are all the 2000-2006 Toyota Tundra recalls issued by the NHTSA:

• A total of 110,000 2000-2003 Tundras were recalled to repair or replace the rear cross member assembly that may rust, weakening the rear brake lines, brake-proportioning valve, and spare wheel mounting, possibly leading to diminished brake performance and detachment of the spare wheel. This was the closest Toyota ever came to a recall for corrosion, and there were never actually any Toyota Tundra frame recalls, despite manufacturer assistance in this regard and the widespread nature of the problem.
• 2000-2006 Tundras with various combinations of aftermarket replacement headlights and reflectors were recalled because of non-compliance with federal regulations. Besides a total of 16,472 2009 models that were also recalled to replace taillight sockets that may allow taillight bulbs to fall out, there weren't any other electrical problems with the 2000-2006 Toyota Tundra's fog lights or brake- and taillights. More than 8,600 1999-2001 Tundras fitted with the Tekonsha trailer-hitch wiring were recalled because a short-circuit in the wiring harness can disable the trailer lights. 1999-2000 model-year Tundras were also recalled to replace a hitch harness that may admit water and also disable the trailer lights.
• 2000-2002 Tundras with alloy-wheel upgrades fitted were recalled because they lack a warning label explaining that the vehicle may handle differently when the smaller-size spare wheel is used.
• The 2002-2006 Toyota Tundra ball-joint recall was issued to replace front-suspension ball joints, which may have been incorrectly manufactured, leading to premature failure and difficult steering or, if the joint detaches, loss of steering. In terms of issues with the 2000-2006 Toyota Tundra's power steering, problems with the steering rack were rarely encountered and, in case of the loss of steering ability, these were mostly related to these suspension failures and not the actual power-steering system.
• The 2003, 2004, 2005, and 2006 Toyota Tundra airbag recall was issued to replace defective Takata airbag inflators that may rupture and send deadly shrapnel into the vehicle interior upon airbag inflation. Takata airbag recalls affected over 42 million vehicles worldwide. More than 156,000 non-compliant 2003-2005 Tundras with switchable front passenger airbags but without lower child-seat anchors fitted were recalled to remove the airbag's on/off switch, replace the owner's manual, and amend the sun visor airbag-warning label. 2005 and 2006 Tundras with an improperly programmed side-airbag control module were recalled because the side airbags can deploy inadvertently. These were the only problems with the SRS electrical system on the Toyota Tundra; no other seat-belt or electrical problems with the restraint systems were noted.
• 2004 and 2005 Tundras with both the TRD dual-exhaust system and stability control fitted were recalled because the exhaust may rub against a brake line, causing brake fluid to leak and diminishing braking performance. This is the only stability or traction-control problem of note on the Toyota Tundra and through no fault of the electronics themselves. 2006 Tundras with a Cardone brake master cylinder were recalled because it can start to leak brake fluid, leading to a loss of braking performance.
• In a 2005-2006 Tundra recall affecting many other Toyota models equipped with heated seats, the seat heaters can short out and cause a fire, so Toyota disconnected the heaters and refunded owners for this feature.
• 2005 and 2006 Tundras were recalled to replace warning labels showing incorrect load-carrying capacities and GVWR numbers. This affected all models and there were no Toyota Tundra recalls for the SR5, Base, or Limited trims specifically.

The follow error codes may come up:

• P0001 on a 2000-2006 Tundra is a fueling-system error code indicating a problem with the fuel-volume regulator control.
• On a 2000-2006 Tundra, P0031, P0037, P0051, P0056, P0057, P0134, P0135, P0136, P0138, P0141, P0150, P0152, P0154, P0155, P0156, P0161, P0171, P0172, P0420, P0430, P1135, and P1140 are all emissions-system error codes related to the oxygen sensors and/or their readings.
• P0102 means there is a problem with the mass airflow (MAF) sensor.
• P0113 is an air-intake temperature (IAT) sensor error.
• P0505 is an idle-air control-system error code.
• P0115, P0118, P0125, and P0128 on a 2000-2006 Tundra are coolant-temperature sensor errors.
• P0120, P0121, P0224, P1120, and P1121 on a 2000-2006 Tundra are throttle-pedal position (TPP) sensor errors. P1126 and P1127 on 2000-2006 Tundras are throttle control system errors.
• A random misfire is indicated by error code P0300, with P0301, P0302, P0303, P0304, P0305, P0306, P0307, and P0308 indicating which cylinder is misfiring by their last digit.
• P0325 and P0330 are knock-sensor error codes.
• P0340 and P1021 on a 2000-2006 Tundra are camshaft-position errors.
• On a 2000-2006 Tundra, P0440, P0441, P0442, P0446, P0450, P0455, and P0456 are all evaporative emission-system (EVAP) sensor errors.
• P0500 is a vehicle-speed sensor error.
• P0553 on a 2000-2006 Tundra is a power-steering pressure-sensor error.
• P0700, P0710, P0717, P0730, P0740, P0741, P0750, P0770, P1760, and P1780 on a 2000-2006 Tundra are automatic transmission error codes. P0700 is a transmission control system error, and P0710 is a fluid-temperature error. P0717 is an input-shaft speed-sensor error, while P0730 is an incorrect gear ratio error. P0740 is a torque-converter clutch-circuit error. P0741 is a torque-converter clutch-solenoid error, P0750 is a shift-solenoid error, P0770 is a lockup-solenoid error, and P1760 is a line-pressure-control linear-solenoid error. P1780 is a Park/Neutral position-switch error.
• P1300, P1330, P1305, and P1310 on 2000-2006 Tundra are ignition-system errors. P1300 and P1330 are igniter-circuit malfunctions. P1305 and P1310 are ignition-coil errors for ignition coils two and three, respectively.
• P1600 on a 2000-2006 Tundra is a battery-circuit error.

There were a few front-brake vibration problems on the 2000-2006 Toyota Tundra, but ABS problems are rare. With 16- and 17-inch wheels being the typical sizes, there isn't a lot of space for huge brakes, so overworked brakes can lead to overheating and warped rotors, even though the basic design of the braking system is sound. Replacing the front rotors will cost at least $300. ABS failures are rare but if you do have to replace an ABS actuator, you'll probably pay around $500. There were quite a lot of 2002-2006 Toyota Tundra front suspension and tie-rod end problems, mostly related to failing ball joints and mostly covered by a recall. Make sure the recall work was performed. 2000-2001 Tundra can also suffer ball-joint failures, so check the suspension thoroughly.

Several owners also complained of mysterious electrical faults that may cause the battery to drain if the vehicle is not used for a couple of days. 2005 models also seem more prone to a bad electric radiator fan, which can fail from as early as 65,000-70,000 miles and costs $800 to replace. The tire-pressure monitoring system can be troublesome at times as well, requiring the replacement of the valve stems. Though not as widely reported in the first-gen Tundra as in some other Toyotas, rodents do seem to be attracted to the Tundra's wiring and rodent damage can amount to thousands of dollars, so control rodents where your truck is parked. A few HVAC fan motors have also failed on 2005 models, costing $170 to replace on average.

While no vehicle system is immune to problems, the rest of the Tundra holds up very well:

• Besides a few isolated transfer-case and front/rear-end differential and driveshaft problems, 2000-2006 Toyota Tundra 4x4 and driveline issues are few and far between.
• Although a few blower motors failed, 2000-2006 Toyota Tundra heater, temperature control, and air-conditioning/air-conditioner/AC problems are the exception and not the rule. Test the system to ensure that the temperature and air distribution functions work properly.
• There were a few cases reported where batteries ran down too quickly when the vehicle was not used for a few days, but other than that, the truck reliably gets going in the morning and there is very little to report in terms of cold-starting problems or problems with the 2000-2006 Toyota Tunda's battery, alternator, or starter relay. However, there were a few starter failures reported on 2004 models; a starter typically costs around $800-$850 to replace.
• The electrics generally hold up very well, too and there are rarely any problems with the 2000-2006 Toyota Tundra's alarm, computer/CPU, cruise control, headlights/fog lights, turn signals, power windows, door lock, radio, sunroof, or wipers. However, do take note of the taillight bulbs that can fall out on 2009 models, although that should have been fixed under the relevant recall.
• In terms of acceleration problems or problems with the Toyota Tundra's ability to idle, the throttle body may just need proper cleaning, but the part itself is rarely at fault. However, keep in mind that hesitation and acceleration problems can also stem from the automatic transmission, as described earlier.
• The various engines' induction, ignition, fueling, and emissions systems rarely give cause for concern and there are few problems with the 2000-2006 Toyota Tundra's air filter, ignition, fuel-pressure regular, fuel pump, catalytic converter, anti-smog, or emissions equipment, though gas-cap problems occasionally pop up, requiring the replacement of worn-out gas caps. Catalytic converters don't fail too commonly, but they're expensive to replace if they do - around $2,700.
• Besides the persistent ball-joint issues, suspension or lift-kit problems on 2000-2006 Toyota Tundras usually have to do with rust damage and not a design fault.
• Base models' steel wheels wore plastic covers and if you manage to find one with all of them still present after all these years, you'll find that most hubcap-fit problems on old 2000-2006 Toyota Tundras have to do with the plastic retaining clips deteriorating and breaking off; you might want to consider tying them to the rims with cable ties so they don't disappear on a bumpy road.

There really isn't a bad Tundra in the lineup but the initial 3.4-liter V6 base engine is underpowered by modern standards. We'd avoid all pre-2005 Tundras because of their poor safety features and the non-availability of stability control and side or curtain airbags. Unless you want a no-nonsense workhorse to plod around at low speed on the farm and have no need for a good level of standard features, we'd give the bare-bones Base trim a miss; the V6 doesn't even have aircon. Very importantly, if there is any sign of underbody rust, avoid that Tundra at all costs, and don't buy one used in a rust-belt state. If there's a suspicion that the air-injection pump is shot, negotiate down the price or prepare for a hefty bill - this problem is most common on 2005 and 2006 V8 models.

It would have to be a 2005 or 2006 Double Cab for us. It is practical, can double as a family vehicle, and has sufficient interior space. Moreover, it had access to some very important safety features, namely front side airbags, curtain airbags, and stability control. But take note that all of these were on the options list, and you'd have to check whether they have been fitted to a Tundra you're looking at. The V8 offers more than enough power, and even the 4.0 V6 is perfectly acceptable. A nicely specced Limited can pass as comfortable and luxurious family transportation, even today, at less than $23,000 fully loaded.

In terms of general reliability, the first-generation XK30/XK40 Toyota Tundra is better than most and the envy of many domestic rivals. However, there are a few caveats, and the biggest one is the frame rust that can affect the suspension and braking system too. It is critical to ensure you buy a clean truck and have the frame professionally rustproofed. Another expensive irritation is the often dodgy and expensive air injection pump on the most desirable 2005 and 2006 models. Other than these, none of the other issues are deal-breakers, and if you can find one with the necessary safety equipment fitted, you'll have a reliable truck that's a pleasure to drive and easier to maneuver than most rivals.