2003 Toyota 4Runner Complaint Log

Severe frame rust. 2 large holes on the inside of the frame just back from the front wheels and 2 large holes at the ends of the rear crossmember.

Odometer Fraud. The contact investigated a 2003 Toyota 4 Runner. The contact stated that during the investigation, he discovered a fraudulent scheme of approximately 15 vehicles with odometer fraud. The contact stated that the suspects targeted Facebook Marketplace victims by spraying oil on the engine prior to test-driving the vehicle, and when the vehicle began smoking, the suspects would ask for a discount for the vehicle. The contact added that after the vehicle was purchased, the odometer was rolled back and the vehicle was resold. The vehicle was a private sale. At the time of purchase, the vehicle mileage was 150,000, and at the time of the vehicle being sold, it was discovered that the mileage was 306,000.

While my mechanic was servicing a small exhaust leak on my vehicle he noticed that the chassis/frame of the vehicle was heavily corroded. He told me that he believe it was no longer safe to drive and that I contact Toyota. I had a local Toyota service center also look at it and they confirmed that the chassis/frame was heavily corroded and unsafe to drive.

My vehicle: 2003 4Runner SR5 2WD VIN: [XXX] Issue: Front driver's side door will not open. Electronic locks are operating, but the door release is not functioning. Safety Concern: What if I was in a situation where I did need to get out of the vehicle immediately? Such as a high-water incident, fire, etc. Especially for a person [XXX], as myself, this would be a big issue. When attempting to exit the car after pulling into the driveway, I could not open the driver's door. The locks would release, but the door latch would not. I had to crawl over the console to get out through the passenger side. This was not easy as I had back fusion surgery and 8 disc replaced, fused. I had to open the sunroof to help with get over and out. After I did get out, I tried the key in the driver's door, it would actuate the door locks on all doors, but the driver's side door latch would still not release. I even disconnected the battery and reconnected. No help. And after knowing more, it was not an electrical issue, but mechanical failure. I now have it at the repair shop after talking with Toyota Service manage who admitted it was a poor design as the repair for this is to destroy the door panel to get to the actuator to attempt to release the door latch. The estimate for this work is 1,150.00. I am beyond frustration, and especially when I see there is no recall for this issue. There are penty of conversations on this same issue on 4Runner forums as well as all over YouTube. Thank you for looking into this. You can reach me at: [XXX] [XXX] [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

Toyota has had issues with their frames rusting out and the 4th generation 4Runner is not exempt from this issue. My 2003 is requiring extensive work to keep it on the road safely due to frame rust. A recall to replace frames should be in place.

Severe frame rust, there was a recall for tacomas but 4Runners have the issue just as bad

The contact owns a 2003 Toyota 4Runner. The contact stated that upon taking the vehicle to several independent mechanics for servicing, he was informed that the subframe was significantly corroded and needed to be replaced. The vehicle was not repaired. The dealer was not notified of the failure. The manufacturer was notified of the failure and informed the contact the vehicle was not covered under recall. The failure mileage was approximately 115,000.

Frame is rotted from front to back

The VSC system in the vehicle becomes disabled due to a firmware 'glitch' identified by Toyota when an emission system issue is detected by the onboard diagnostic system. The VSC system is listed as an 'essential safety feature,' so I'm curious why a recall was never ordered to patch defective firmware that can cause VSC to become disabled due to a completely unrelated emissions issue.

The contact owns a 2003 Toyota 4Runner. The contact stated that while the vehicle was at the tire retailer for tire replacement, the technician informed him that the subframe was corroded. The vehicle was then taken to an independent mechanic, who diagnosed that the passenger's side front and rear subframes were severely corroded, as well as the cross member. The mechanic advised the contact to stop driving the vehicle. The dealer was made aware of the failure and informed the contact that there was no recall associated with the VIN. The vehicle was not repaired. The manufacturer was not made aware of the failure. The failure mileage was approximately 165,000.

Vehicle frame has rusted through and has holes affecting structural condition.

Extensive rust through out frame, resulting in holes in structural members. Leaving frame in a weak and vulnerable state.

Complete corrosion of entire frame causing unavoidable damage to framework.

Excessive frame rust causing difficulty to keep vehicle on the road. No warning lamps, I noticed the rust starting years ago, now the rust is so bad that the frame is rusted through causing difficulty steering and loud crunch noises. I contacted Toyota Consumer Affairs explaining the rust concern and asked if I needed to take the vehicle to a dealership for inspection, they said it wasn’t necessary (sounds like they don’t want to admit the existence of a possible manufacturing defect). The vehicle is available for inspection. I feel like I would be doing a disservice to society if I continue to drive this vehicle on public roads due to the danger of injuring a pedestrian or another motorist.

There is severe rust on the frame, the rear is listing by 3/4 of an inch due to suspension rust, parts of the frame are perforated and lots of rust can fall out of drain holes when tapped. I am unable to steer the truck due to the intermediate steering column rust. The Tacoma was recalled for the same reason, I am assuming the 4runner has not been recalled because it was manufactured in greater numbers, and therefore more costly to repair, the danger of the severe rust is the same in both vehicles.

Rusted frame

So much rust has developed the frame is literally giving out. Toyota admitted to a rust issue- it’s now a safety issue with this generation of 4Runner. They did a recall on the same frame for Tacoma but not 4Runner.

The frame of the car has been rusting at a significant rate in the last 4 years. Mechanic identified major rust issues that would make the vehicle not safe in case of an accident.

The frame on my 4Runner is rusting through in multiple locations. The rear of the frame has already failed and a trailer I was pulling dragged on the road heavily as it failed. Definitely at risk of caving in long before the engine or transmitoo fails.

I have two 2003 Toyotas, a tundra and 4runner. The 4Runners frame is rusting out everywhere including the welds. My mechanic said it was getting to the point that it’s dangerous to drive and if it was in a wreck the frame would likely fail under the stress. My tundra frame from the same year is immaculate. I believe the are similar frames. This is obviously a defect in the production based on my readings and is very common. The investigation was opened in 2018 and its now 2022, when will this get addressed!

Stabilizer bar connecting the axle to the frame rusted off. I was driving only 25-30mph at the time, luckily. The vehicle swayed violently almost causing an accident and nearly forcing me off the bridge I happened to driving over. Very fortunate no one was hurt and nothing was damaged from the incident. You can imagine the tragedy if that had happened on the highway driving 75mph! Major accident, innocent lives damaged or lost. This is a very dangerous vehicle not only to the driver and passengers but also to anybody that happened to be innocently in the path of an out of control Toyota 4runner. Toyota Please fix this, for your safety and everyone else on the highway. People should be warned!!

Stabilizer bar connected to the frame rusted off,back passenger side! Causing the vehicle to sway uncontrollably, due to the low rate of speed, I was able to regain control of my vehicle and not drive off the bridge I was driving over at the time or crash into another vehicle. The engine runs great, everything works, the vehicle still looks good but the frame is rusting out from underneath it! Toyota Needs To Make It Right!

The frame of the vehicle is rusted to the point my fist can fit through a hole in the frame.

The frame has rusted out. It has many large holes throughout and will not pass State Inspection and is deemed unsafe.

The frame on the vehicle is rusting out. If not repaired, serious injury could occur if the frame breaks. A compromised frame could cause serious injury if an accident occurs. The driver side main frame has a gaping hole on the inside and another hole forming underneath that is in close proximity to the larger hole. The entire back cross bar member supporting the bumper is rusting out as well as the front cross bar member. The vehicle was inspected in July 2020 and the dealership said the frame was OK and had plenty of life left in it. After getting a muffler installed at a local independent shop in October 2021, the hole grabbed the attention of the technician. After inspecting, rusty flakes kept falling away.

Extreme frame rust. The vehicle has extreme frame rust and Toyota should be held accountable for poor quality frame material. I have heard tons of stories of other peoples steering components snapping due to rust and frame damage.

Vehicle frame and suspension components are completely rusting out. Having issues with the corroded steering column lower shaft not allowing the vehicle to turn properly.

I have not actually had an incident yet, but have been advised by the Toyota service team that I should no longer tow trailers and should consider not driving it at all due to frame rust/perforation in front of the rear control arms. This has been a well cared for vehicle that is in otherwise great shape (It has had every repair the dealership has ever recommended) the vehicle was bought per the dealerships claim that it could be driven "forever" as long as the dealership takes care of it. And now I'm faced with a massive expense to repair or replace the vehicle.

The contact owns a 2003 Toyota 4Runner. The contact stated while his wife driving 60 MPH with the cruise control activated, the accelerator pedal was depressed, and the vehicle rapidly started to accelerate. The contact stated no warning light was illuminated. The driver depressed the brake pedal to stop the vehicle and parked on the side of the road. The driver was able to restart the vehicle and drive to her destination. The contact stated that in October 2021 his wife experienced a similar failure. The contact also stated that on 11/8/2021 while his wife driving 55 MPH and depressing the accelerator pedal, the vehicle accelerated quickly. The contact stated no warning light was illuminated. The driver depressed on the brake pedal with both feet and shifted gear to neutral to slow the vehicle. The driver stated she saw smoke coming from both front brakes. The drive was able to park on the side of the road. The driver stated that the brake pedal was seized on the floorboard. The driver stated she applied the parking brake to release the brake pedal. The driver was able to drive to her residence. The contact stated that his wife had experienced the failure on 3 different occasions. The vehicle was not diagnosed or repaired. A dealer was not contacted. The VIN was associated to NHTSA Campaign Number: 11V113000 (Vehicle Speed Control) and NHTSA Campaign Number: 03V146000 (Fuel System, Gasoline). The manufacturer had not been informed of the failure. The failure mileage was approximately 240,000.

The frame is rusted very bad and it’s a major safety issue for this type of vehicle I don’t know when it’s going to fall apart. I am sure I am not the only one to have this problem.

Really bad frame rust, holes in frame, engine mounts.... Cracked dash board. All problems shared by many 2003 4runner owners too. I'll take more photos.. Thanks for your attention.

Due to severe rust underneath the vehicle, there have been a few issues that have made the vehicle very unsafe to drive. Last week, both of my rear brake lines were completely done and leaking brake fluid leaving me with no brakes. This was due to rust and corrosion that had eaten the metal lines away. The radiator mounts are corroding, as well as the skid plate for my fuel tank and a few spots on my frame near the rear. I was not aware of the rust as I just got the vehicle a few weeks ago. I was driving in traffic when my brake light came on and I noticed my brakes didn't seem to be very effective and they eventually got the point where they were not working or slowing the vehicle at all. Once I took it to the shop and they put it on the lift, the mechanics pointed out just how bad the rust was.

The frame is rusted beyond repair and is dangerous to drive. The frame cross members are rusted through. One cross member that supports the transfer case is about to fail and would cause the transfer case to drop out of the bottom of the truck causing a catastrophic failure and possible accident. The vehicle cannot be driven. The problem is unrepairable. The truck has to be junked. The problem was brought to my attention by the Toyota Service Rep during a routine service appointment. The rust appeared several years ago but not to this extent.

The frame is completely rusted through and soon will be unable to support the steering, engine or drive train. The problem was confirmed to me by an independent service center that I have used for 10 years and I trust.

Car inspection at a service center revealed advanced rusting of the frame. I was told this could be dangerous.

At the end of June 2021, while driving I experienced a loud clunk and grinding noise, with reduced control of steering and brakes on my 4Runner. I took the 4Runner to a Goodyear Automotive Service Center on Woodward Avenue in Royal Oak, Michigan, who told me that the vehicle was not driveable due to severe rust damage of the frame that resulted in a broken sway bar. I thought I should take it to the closest Toyota dealership in Troy, Michigan for advice and they responded that the vehicle was beyond repair and that a new frame would cost around $20,000. I could not leave my car there, and risked driving it home, where it has been parked ever since.

I heard a loud noise (scraping-dragging) from the bottom of the engine area while driving on the highway This was a very dangerous and scary incident Pulled over and My fiancé checked under the engine A very large metal piece was dragging the road I did not hit a bump or anything. A body shop mechanic informed me that the chasis of the 4 runner was in extremely bad condition The 4Runner will not pass inspection because of this condition I respectfully request help in this matter

The frame has rusted almost completely through near the front upper and lower control arms near the cross member there. The passenger side is so bad the welder I took it too sad he couldn’t repair it without doing the crossmember section and all. The driver side is not at bad but doesn’t look to hot. The crossmember where the radiator sits is also starting to completely rot away

Frame is rotted out and brake lines attached to the frame as well as every suspension component. Car failed inspection deemed unsafe to drive. This problem has been addressed for Tacoma, tundra and sequoia but not 4runner. These frames have the same issue as those and needs to be repaired by Toyota due to lack of rust and corrosion protection. There’s no reason 4runner should be overlooked for the same issue as the other full frame trucks.

Three mechanics said the frame was rusted with holes and is unsafe to drive. The vehicle is not inspectable, so had to have mechanic weld Steele on frame to be able to pass inspection.

Frame rusted to the point the shop won’t fix the brakes and allow me to drive the car. The brake line rusted through since it was attached to the frame and when repairing the brakes they found the frame rusted too bad and coming apart. Looking online this seems to be a common problem with this year Toyota 4Runner.

ADDING MY NAME TO THE LIST OF PEOPLE WHO HAVE EXPERIENCED EXCESSIVE AND PREMATURE FRAME RUST ON THEIR 4RUNNER, POTENTIALLY CAUSING UNSAFE CONDITIONS WHICH COULD LEAD TO A COLLISION. TOYOTA ADDRESSED THIS PROBLEM FOR THE TACOMA, SEQUOIA, AND TUNDRA OF THE SAME YEARS, AND THEY SHOULD DO THE SAME FOR THE 4RUNNER.

I HEARD THERE'S AN INVESTIGATION ON THESE FRAMES SO MINE IS ROTTING AWAY

IN REFERENCE TO NHTSA ACTION NUMBER: DP18002. MY MECHANIC INFORMED ME THAT MY 2003 4RUNNER IS STARTING TO EXPERIENCE EXCESSIVE CORROSION ON THE FRAME. HE INFORMED ME THAT THIS IS COMMON WITH THIS MODEL. I CONTACTED A BODY SHOP TO INQUIRE ABOUT POSSIBLE SOLUTIONS. I WAS INFORMED THAT THEY GET INQUIRIES ABOUT THE 2003 4RUNNER OFTEN YET THEY DO NOT LIKE WORKING ON THEM AS THE FRAME IS CONSTRUCTED IN SUCH A WAY THAT IT IS DIFFICULT TO ADDRESS THE CORROSION ISSUES. I'M REPORTING THIS TO HELP FACILITATE THE ONGOING INVESTIGATION AND TO INQUIRE ABOUT ANY PROGRESS BEING MADE ON THE INVESTIGATION.

I HAVE BEEN IN CONTACT WITH TOYOTA SEVERAL TIMES OVER THE PAST 4 YEARS ABOUT RUST ISSUES WITH THIS FRAME, BUT THE REFUSE TO FIX IT. THEY RECALLED THE TACOMA, TUNDRA AND SEQUOIA OF THE SAME YEAR FOR THIS REASON. THE FRAME RUSTS AND FALLS APART. WHILE DRIVING UP MY ROAD I FELT THE REAR OF THE CAR SHIFT TO THE SIDE, I TURNED AROUND AND WENT STRAIGHT HOME TO FIND THE FRAME AT THE REAR PASSENGER TIRE BROKEN. I HAVE ATTACHED A PICTURE OF THE BROKEN AREA, BUT CAN SEND MORE PICTURES OF THE ENTIRE FRAME IF NEEDED.

TL* THE CONTACT OWNS A 2003 4RUNNER. THE CONTACT STATED THAT WHILE THE VEHICLE WAS BEING REPAIRED, HE WAS INFORMED THAT THE UNDERCARRIAGE AND SUBFRAME OF THE VEHICLE WAS EXTREMELY RUSTED. THE VEHICLE HAD NOT BEEN TAKEN TO A DEALER OR INDEPENDENT MECHANIC TO BE INSPECTED. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 139,000.

I own a 2003 Toyota 4Runner with very low mileage for its age. It has been garage kept for most of its life. I was experiencing difficulty steering, and when I took the car to a mechanic, it was determined that the frame was prematurely rusted and rotted to a dangerous level putting my life at risk while driving it.

THE FRAME IS RUSTED BEYOND REPAIR AND THE VEHICLE HAS SPENT THE MAJORITY OF ITS LIFE IN A N UNDERGROUND GARAGE PROTECTED FROM THE ELEMENTS, AS WELL AS IN FLORIDA. IT HAS VERY LOW MILEAGE, AND NO OTHER SERIOUS PROBLEMS.

EXTREME RUST AND CORROSION IN FRAME, SUSPENSION COMPONENTS. THIS WILL LEAD TO CATASTROPHIC FAILURE AT SOME POINT IF HOLES AND FRAME DETERIORATION IS NOT ADDRESSED QUICKLY.

LOUD NOISE WHILE DRIVING. UPON INSPECTION, EXCESSIVE RUST AND CORROSION TO FRAME OF VEHICLE FOUND. HOLES IN FRAME LARGER THAN 2 INCHES.