2004 Toyota 4Runner Complaint Log

My 4 runner only has 147,000 miles and is a great running vehicle but my frame is rotted badly. I have large holes throughout, the front crossmember under radiator with tow hooks has completely rusted off, and now I found where my rear lower drag link bolts to frame is about to come off. I have had to repair rusty brake lines multiple times. My rear axle carrier just sheds large flakes of rust. I love this truck but now it is almost too dangerous to drive and with all the inflation lately I cannot afford another vehicle.

2004 Toyota 4Runner, original owner with roughly 210K miles. We took the vehicle to the mechanic concerning a sway bar issue. He informed us that the frame of the vehicle was nearly rusted into and that it's serious safety issue to continue to drive it. It is my understanding the Toyota recalled several other models with this same issue but did not include the 4Runner in this recall.

The entire frame is rusted. It's been welded back together on 2 different occasions. The last time it happened I was pulling out of driveway and the vehicle cannot be steered at all. I live in east TN and should not have a rusted frame. This is not an isolated problem. This is a problem with the 4runners and should be recalled. There are literally 1,000's of 4runners with Rusty frames. I don't understand why this isn't being recalled. You can reach me at [XXX] or [XXX]. INFORMATION Redacted PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6).

The frame is rusted completely throughout. VERY DANGEROUS!

Vehicle has a rust frame which causes a dangerous

Rear section of the frame snapped in half during normal driving. Barely driveable extremely hazardous and will remained parked.

Seized front right brake caliper caused vehicle to slide off road during sudden stop to avoid debris in roadway. Took vehicle to a brake shop and they found that right front wheel was locked. This is the third time I have had the EXACT same problem with the brake system. The previous times, the problem occurred during nice weather and with windows open I smelled the burning brake pads and was able to get the problem fixed before it became a hazard. On the first previous incident, the repair required replacement of both front brake caliper, rotors, and pads. On the second previous occasion less than 20,000 miles ago BOTH front and rear calipers, rotors and pads were replaced. This is apparently a known defect in the 2004 Toyota 4Runner, yet Toyota has not conducted a recall to fix an extremely dangerous and ongoing problem. NOTE: I originally purchased the vehicle in New Jersey in 2004 and a Virginia Toyota dealer (Koons Toyota) worked on the brake system multiple times (2005-2006) and finally replaced the entire system.

Frame rust discovered by state inspection mechanic, vehicle fails for frame members rusted through. May not be repairable.

Took vehicle for service a couple of days ago. Mechanic would not work on the vehicle due to extensive frame rust and corrosion. Mechanic said he could push his finger through some of the rusted frame members. Extensive frame rust/corrosion on at least 3 sides of the vehicle and sagging frame in the front per mechanic.

Side curtain shield airbags.

The frame rusted and at least two parts of the frame rusted through. Informed by the mechanic upon state inspection. On or around October 18, 2021

Purchased 4 runner from a Toyota dealer in 2018 with 130k miles. During routine maintenance in 2021 with 160k. The frame was found to have several holes and wide spread corrosion. It is absurd that Toyotas was let off the hook for frame replacements. I bought this truck from the dealer and it had structural frame issues that were not disclosed at the time of sale. Frames don’t just fall apart apart in 4 years from normal driving. Clearly Toyota is ignoring the manufacturing deficits in there frames and still re-selling these as road worthy cars. It’s absurd that Toyota was not required to replace these and not recall has been issued. People should not be able to buy/sell one off these vehicles they are not safe due to the frames rusting from the inside-out. They need to be recalled and removed from service.

Complete frame rust-out. Suspension at rear axle disintegrated. Vehicle undriveable. My son had just taken the vehicle (moving his belongings) from Minnesota to the East Coast and back. No problems or issues. After returning, while driving the vehicle I had a hard braking event which is when I noticed something was drastically wrong. This frame failure really snuck up on us. We were lucky, no accident or incidents occurred.

My steering became very loose with a lot of movement in the steering wheel. The universal joint in the steering column shaft was bad. Upon further investigation, both lower control arms on the front wheels were rusted through, (from the inside out), with one of them bent because of the lack of metal support that rusted away, which caused my wheels to be misaligned and hard to control. Upon additional inspection, the frame has rusted out in multiple places which could allow it to break in half. (pictures of one portion of the frame are attached.) I have had the steering column and lower control arms replaced but multiple body and frame shops state the frame is rusted too much to repair. I know Toyota recalled several models for frame rust issues but have not included the 4Runner, which I cannot understand. This rust has been noticed for several years on my vehicle with attempts to keep it clean and rust free. However, the rusting process is occurring from the inside of the frame toward the outside, so you can't tell how bad it really is until you see the holes protruding through the frame. This model should be included in a class action suit requiring Toyota to compensate the owners for this defect and removing these models from service to avoid potential accidents and casualties caused by inferior iron products that were used in their manufacture.

I took my car in for repair. Check engine light and VSC track lights on with horrible sound beneath the car. The auto repair shop called me and said the frame and underbody of the car is so rusted it will break apart if I drive over a pothole. So rusted that there is nothing to be able to attach to under the car. I am original owner and had rust proofing applied to the car there when I bought it. They charged me nothing because there is nothing they can do, they can’t even weld it it’s nothing but rust.

The contact owned a 2004 Toyota 4 Runner. The contact stated that the driver’s and front passenger air bags failed. The contact stated that when at complete a stop at the red traffic light, the vehicle in the rear failed to stop and crashed into the contact's vehicle rear-end, pushing the vehicle into the roadway. The driver’s and front passenger air bags failed to deploy and caused the front passenger's head to hit the dashboard, suffered injuries to the head, six broken back vertebrae, three broken ribs, head concussion. The contact was the driver and had no injuries to report. The front passenger who was her husband was airlifted to the hospital. The State Trooper mentioned that the other driver might have been on their phone however it was unknown due to them suffering fatal injuries. A police report was filed. The vehicle was towed. The contact advised that the vehicle was destroyed. The manufacturer was not contacted. The failure mileage was 238,000.

The control arms rusted completely off the frame. The whole frame has rust holes!

Extensive rust on frame and suspension parts. Areas completely rusted through, presenting safety hazard.

Original owner of 2004 Toyota 4Runner SR5 (purchased February 23, 2004). Garage kept and approximately 125,000 miles. Vehicle was taken to mechanic for exhaust issues and reported the flange had rusted and disintegrated providing $2300 quote to repair. Taken to a second shop that indicated rust on frame and sub-frame was significant and would not accommodate an exhaust repair. Also stated that bolts and supports for radiator and gas tank were severely rusted. Estimates the car to be road worthy for an additional 3-6 months.

Frame started excessive rusting before 2011 when the vehicle had very low miles on it. I reported it to Toyota National headquarters in 2016. They knew about it but since they didn't have to replace the frames they didn't care. They offered me $1000 towards a new car. I could not afford a new car. I have been battling the rust ever since. I spent $4000 in the past 2 years. I was driving with a broken front axle!! Recently the rust corroded my brake fluid lines causing the lines to fail all at once. Luckily I was leaving my driveway. I had no brakes and was headed for the road. I hit the emergency brake and stopped at the road. Brake fluid fell out all over my driveway. I had to spend $400 getting my driveway resealed and $300 for the new brake lines which was really cheap. I took the truck to Toyota to trade it in and they would only give me $1500 for the beautifully, well cared for truck with only 135000 miles on it because the frame was rusted. They replaced the frames on the Tundra and Tacoma, which were the same frames. They need to replace the frames on the 4Runners or compensate the owners like me. I am the original owner. I bought the dealers demo in 2005. I want the $10,000 they owe me. I am moving and I have to sell this truck, instead of waiting for Toyota to replace the frame, because it is unsafe to drive from NY to NC. I am very sad. Other than the rust this truck is fantastic. I feel like a good friend died! It hurts to let it go. I will have to sell it privately. I think $1500 from the dealer is criminal.

My Frame is a rusted mess. The entire frame is experiencing rust issues. My rear sway bar rusted off and broke into pieces (1/15/21). Now my exhaust pipe has fell off the muffler due to rust (7/21/21). My brake calipers have been very badly rusted as well as the pieces that hold my shocks and suspension in place. It has been progressively getting worse over the past 3-4 years. I feel like this has now become a safety issue and I'm not sure if it's safe to drive. It may be a risk to myself and other drivers on the road. My mechanic has told me that it will not improve and he thinks that the frame and other parts should be recalled. I have plenty of photos if needed. Please help me before something goes wrong.

Under body has severe frame damage from rust.

My 2004 Toyota 4Runner has holes multiple inches in diameter rusted completely through the frame in multiple locations including where frame rails meet and are welded. This 4Runner is very clean and well kept in a climate controlled garage. The 4Runner was somehow not captured in the class-action law suit against Toyota that included the Tacoma, Tundra and Sequoia. Toyota has long known the frames are prone to excessive, premature rust corrosion because the frames were not properly prepared and treated against rust corrosion when they were manufactured and yet it has failed to offer significant help to owners. The excessive rust damage on my Toyota 4Runner compromises the vehicles safety, stability and crash worthiness because important suspension components, engine mounts, transmission mounts and body mounts anchor to the vehicles frames. I have spoke with a local Toyota dealer who stated they would inspect the vehicle with a diagnostic fee of $139 but that Toyota would not help with repair or replacement of the frame. There is no need to inspect the vehicle as I have multiple pictures illustrating the magnitude of the rust damage to the frame including several holes multiple inches in diameter in critical locations of the frame. I have attached several photos of the rust damage as well as photos of the body for reference to how well kept the vehicle is.

The contact owns a 2004 Toyota 4Runner. The contact stated while driving at various speeds, there was a loud sound coming from underneath the vehicle. The contact looked under the vehicle and saw several holes throughout the subframe of the vehicle due to rust. The vehicle was taken to an independent mechanic where it was diagnosed with the subframe needing to be replaced. The vehicle was not repaired. The manufacturer was informed of the failure and informed the contact that the Vin was not under recall. The failure mileage was approximately 130,000.

Severe rusting of body frame

The frame is rusted very badly and may need to be salvaged. Many of the other Toyota vehicles in this same year which have the same frame have already been recalled. Why not the 4runners? I've owned many other early 2000's vehicles and none have had this bad of rust. Simple not acceptable and not safe!

OUR 2004 TOYOTA FORERUNNER WITH V6 ENGINE WAS PURCHASED AS A USED VEHICLE IN 2019 WITH 106,000 MILES ON IT. SINCE THEN, IT HAS DEVELOPED MORE AND MORE AREAS OF RUST ON THE FRAME DESPITE OUR EFFORTS TO MITIGATE THIS ISSUE. WE HAVE HAD TO REPAIR THE FRAME, SUSPENSION, BRAKES, AND WHEEL BEARINGS. WE CONTINUOUSLY INSPECT THE UNDERCARRIAGE AND CONTINUE TO DISCOVER MORE AND MORE AREAS OF SIGNIFICANT RUST/DETERIORATION DESPITE EFFORTS TO CLEAN, TREAT (WITH PAINT, RUST INHIBITORS, WELDING REPAIRS). WE ARE CONCERNED THAT THIS DETERIORATION WILL SOON RESULT IN A CATASTROPHIC FAILURE AND POSSIBLE ACCIDENT RESULTING IN PROPERTY DAMAGE, INJURY, OR DEATH.

TOYOTA MADE GARBAGE BOXED IN FRAMES AND NOW MY TRUCK WON'T PASS INSPECTION

The frame on my 4Runner is severely rusted out; it is available to be inspected if requested. When I'm driving, the vehicle is potentially unstable due to frame rot which could cause potentially life threating injuries to myself, my passengers, and others on the road. The problem has been confirmed by JR Autohaus in Woburn MA. The vehicle has not been inspected by the manufacturer/police/or insurance companies. There was no prior indication of an issue; it appeared when the vehicle was put on a lift to have a new exhaust put on: the vehicle was creaking and was dangerous to be on the lift for the technician. He inspected the frame and took pictures of the rust damage. The issue was discovered on 3/23/21

I HAVE ANOTHER 4 RUNNER WITH A HEAVILY RUSTED FRAME. I AM VERY CONCERNED THAT A UNSEEN FAILURE CAN OCCUR WHILE TOWING A 4300 POUND CAMER OR WHILE DRIVING ON ROUGH ROADS. I'M NOT ONLY CONCERNED FOR MY WIFE AND I BUT ALSO FOR OUR GRANDKIDS THAT VISIT US MONTHLY. HERE IS THE ACTUAL FAILURE. MY WIFE CAME IN LAST THURSDAY AND ASKED ME WHAT IS THAT CAR PART THAT FELL OFF? I WENT OUT TO CHECK AND FOUND THE RIGHT BODY MOUNT LAYING THERE. THE BOLT THAT HOLDS IT HAD ROTTED IN TWO BETWEEN THE UPPER AND LOWER RUBBER PIECES. THE BOLT AND NUT ON THE BOTTOM LOOKS GOOD SO THERE WAS NO INDICATION OF A IMMINENT FAILURE. I'M CONCERNED THAT OTHER MORE SERIOUS FAILURES CAN OCCUR.

I PURCHASED THIS VEHICLE IN 2015 WITH 111K MILES ON IT. JUST FOUND OUT TODAY MARCH 2 THAT THE FRAME IS SHOT AND THE CONTROL ARMS FOR THE REAR AXLE HAVE LET GO ON BOTH SIDES DO TO FRAME ROT, THERE ARE ALSO OTHER QUESTIONABLE PARTS OF THE FRAME. SO VERY DISAPPOINTED IN THIS TOYOTA VEHICLE. THIS CAR COULDN'T EVEN LAST 20 YEARS, NOT THE REPUTATION OF WHAT I THOUGHT TOYOTAS WERE KNOW FOR.

EXCESSIVE RUST/ROT ON THE FRAME, WHICH IS LEADING TO EXPENSIVE REPAIRS AND FEARS OF UNSAFE OPERATION.

EXCESSIVE FRAME RUST CAUSING FRONT RIGHT FRONT BODY MOUNT TO DETACH FROM THE FRAME, PASSENGER FRAME RAIL HAS DISINTEGRATED BETWEEN CROSSMEMBERS. THE 4RUNNER HAS 170000 MILES ON IT WITH NO BODY RUST.

MANY SIGNS OF PREMATURE RUST ON THE FRAME WITH SEVERAL HOLES. THE TRUCK ONLY HAS 124K MILES AND SHOULD NOT BE IN THIS STATE. TOYOTA HAS TO RECALL THESE FRAMES JUST LIKE THEY DO FROM OTHER TRUCKS MANUFACTURED DURING THE VERY SAME YEARS.

MY VEHICLE HAS SEVERE FRAME ROT, ALL OF WHICH COMING FROM THE FACTORY WELDS TO THE SURFACE POINTS ALONG WITH IT'S ROTTING FROM THE INSIDE OUT ESPECIALLY AROUND THE FRONT LOWER CONTROL ARM AREAS OF THE DRIVER AND PASSENGER SIDES OF THE VEHICLE. THIS ALSO REACHING THE BACK OF THE VEHICLES FRAME TOO.

The contact owns a 2004 Toyota 4Runner. The contact stated while driving 30 MPH over a bump in the road, she heard an abnormally loud sound and the windshield shattered without impact and the sunroof panel loosened. The contact also stated that the vehicle was shaking uncontrollably. The contact stated that the traction control warning light was illuminated. The contact took the vehicle to the local dealer, where it was diagnosed and determined that the subframe was rusted and needed to be replaced. The vehicle was not repaired. The manufacturer had been informed of the failure. The failure mileage was approximately 160,000.

PREMATURE AND EXCESSIVE FRAME CORROSION. SIMILAR MODELS WERE COVERED BY EARLIER FRAME RECALL, WHY NOT THE 4RUNNER?

MY 2004 4RUNNER LIMITED V6 HAS SIGNIFICANT RUST BUILD UP ON THE FRAME, CONTROL ARMS, DRIVESHAFT, ETC. I AM THE SECOND OWNER WITH JUST OVER 21K MILES DRIVEN IN THE PAST THREE YEAR AND RIGHT AT 160K TOTAL. I'VE MADE SURE TO GET REGULAR WASHES TO PROTECT THE UNDERCARRIAGE AFTER INCLEMENT WEATHER SINCE I'VE OWNED THE VEHICLE. AFTER RETURNING FROM A 10-MONTH DEPLOYMENT, TWO SHOPS HAVE TOLD ME THE CONDITION IS DANGEROUS AND REQUIRES SIGNIFICANT REPLACEMENT PARTS AND ANTI-CORROSION TREATMENT TO REMEDY THE PROBLEM. I DON'T HAVE THOUSANDS OF DOLLARS TO SPEND ON A TRUCK THAT SHOULD LAST ME AT 250K MILES. I WILL NOT LET MY WIFE AND GIRLS RIDE IN THIS VEHICLE, BUT WE NEED TWO CARS. IMAGINE MY SHOCK TO FIND OUT MANY OTHER TOYOTA OWNERS HAVE DEALT WITH THE SAME THING. THIS IS CLEARLY NOT A COINCIDENCE. HOPING FOR TOYOTA TO RECTIFY THIS SERIOUS SAFETY/QUALITY ISSUE.

EXCESSIVE FRAME RUST. OUR 4RUNNER HAS JUST PASSED THE 200K MILE MARK, BUT THE FRAME HAS BEEN RUSTING AT AN ALARMING RATE FOR YEARS NOW. LIVING IN AN AREA WITH SALTED WINTER ROADS, I HAVE BEEN SOMEWHAT MINDFUL OF THIS (NOT PERFECT), BUT THE AMOUNT OF CORROSION SEEMS EXCESSIVE, EVEN IN THIS ENVIRONMENT. THERE HAS BEEN NO MOVING INCIDENT OR CRASH, BUT PARTS OF THE FRAME HAVE BEEN AFFECTED ENOUGH THAT I AM CURRENTLY HAVING TO ASSESS THE DRIVABILITY IN LIGHT OF SAFETY.

TODAY I FAILED VEHICLE INSPECTION BECAUSE OF RUST AND DETERIORATION OF MY CHASSIS FRAME. THE VEHICLE WAS BOUGHT NEW, SELDOM DRIVEN IN ANY AREAS OF SALTED OR SANDED ROADS. IT WAS ALSO MOSTLY GARAGED EITHER AT WORK AND/OR AT HOME. THE VEHICLE ONLY HAS 175000 WHICH IS LOW CONSIDERING THE AGE OF THE VEHICLE. I KNOW THAT MANY TOYOTAS HAVE HAD THIS PROBLEM AND SOME MODELS HAVE HAD RECALLS. IN SPITE OF THE MANY PROBLEMS THAT FORERUNNERS HAVE HAD, IT IS YET TO BE RECALLED....AND ALL RECALLS START AT 2005. MINE IS A 2004 AND THE FRAME IS FALLING APART. I AM EXTREMELY DISAPPOINTED AND WISH VEHICLES IN MY DEMOGRAPHICS WOULD BE CONSIDERED IN A NEW RECAL......

FRAME RUSTS TOO EASILY. COATING WAS NOT GOOD ENOUGH FROM FACTORY. TACOMA'S WITH SAME FRAME WERE RECALLED.

I WAS INFORMED THAT WHEN I WENT TO GET MY OIL CHANGED THIS MORNING THAT I HAD MAJOR RUSH ON MY FRAME IT WAS CRACKED AND HAD BIG HOLES IN IT AND THEY WERE AFRAID TO PUT IT UP ON THE LIFT. ADVISED ME TO CHECK WITH MY DEALER TO SEE IF THERE WAS A RECALL. ACCORDING TO KBB THERE IS NOT WITH MY CORRESPONDING VIN NUMBER WHICH IS A DANG SHAME BECAUSE THIS IS A SAFETY ISSUE AND I SHOULD T BE AFRAID TO DRIVE MY GRAND CHILDREN AROUND IN FEAR THAT MY FRAME WON'T SUPPORT US. WE PURCHASED THIS VEHICLE BECAUSE TOYOTA IS KNOWN FOR THEIR SAFETY, RELIABILITY.INTEGRITY AND LONGEVITY. SO BECAUSE OF THE EXCELLENT FEEDBACK I HAVE RECEIVED ABOUT TOYOTA'S ' LASTING FOREVER' I MADE MY FIRST TOYOTA PURCHASE. THE BODY DECEIVED ME . OTHER THAN A LITTLE GOLF BALL DENT ON THE FRONT FENDER. THE BODY IS VERY GOOD CONDITION NOT A SPECK OF VISIBLE RUST.

THE FRAME HAS RUST AND HAS A HOLE. IT IS UNSAFE TO DRIVE AND WILL NEED TO BE ADDRESSED VERY SOON. THERE WAS NO SPECIFIC INCIDENT. I RECENTLY BOUGHT THIS CAR. I DON'T KNOW WHEN IT HAPPENED.

FRAME IS ROTTED 115K MILES ON THE CAR, IT SEEMS TO BE ROTTING AT THE WELDS ONLY.

THE FRAME HAS COMPLETELY RUSTED

THIS 2004 4RUNNER WAS PURCHASED FROM A LOCAL DEALER IN SOUTH FLORIDA. THE CARFAX REPORT STATES THAT IT WAS PREVIOUSLY TITLED IN TEXAS AND THEN LATER IN NEW YORK. IT DID PASS THE NEW YORK STATE SAFETY INSPECTION IN 2020. HOWEVER, AFTER OWNING THE VEHICLE FOR A SHORT PERIOD I TOOK IT TO A MECHANIC FOR A OIL CHANGE. I WAS ADVISED THAT THE RUST/CORROSION ON THE FRAME AND UNDERBODY COMPONENTS WAS QUITE SEVERE. MY CONCERN IS THAT IT MAY WORSEN AND AFFECT THE OVERALL SAFETY OF THE TRUCK AS WELL AS THE RESALE VALUE. I'M AWARE THAT TOYOTA HAD A SIMILAR ISSUE WITH TACOMA'S, TUNDRA'S, AND SEQUOIA VEHICLES. WHY WASN'T THE 4RUNNER INCLUDED IN THESE RECALLS GIVEN THE LARGE AMOUNT OF COMPLAINTS REGARDING 2003-2009 MODELS?

THE STRUCTURAL FRAME OF THE VEHICLE IS RUSTED OUT. HOLES, LARGE AREAS OF THE FRAME HAS RUSTED OUT. THE FRAME IS STRUCTURALLY COMPROMISED. JUST NOTED ON 10/19/20. VEHICLE WAS IN LESS THAN A YEAR EARLIER WITH NO SIGN OF THE DAMAGE.

SEVERE FRAME RUST ON 2004 4RUNNER SR5 SPORT. SUSPENSION RUST, STEERING COMPONENTS RUST. HOLES IN VEHICLE FRAME DUE TO RUST. I WENT TO TWO MECHANICS THAT TOLD ME THAT THIS RUST WAS BEYOND REASONABLE FOR NORMAL RUST ON FRAME, THEY BOTH STATED IT MAY BECOME DANGEROUS AND TO CONTACT TOYOTA DIRECTLY. THE VEHICLE IS BECOMING DANGEROUS TO DRIVE DUE TO POSSIBLY OF FAILING COMPONENTS AND OR FRAME.

FRAME HAS SEVER RUST-THROUGH AND CORROSION ON THE PASSENGER SIDE IN FRONT OF THE REAR TRAILING LINK MOUNT AND BEHIND THE FRONT CONTROL ARM MOUNT. VEHICLE IS DRIVEN IN AN ENVIRONMENT WHERE ROAD SALT IS USED IN THE WINTER, BUT THIS IS EXCESSIVE COMPARED TO OTHER OLDER VEHICLES. VEHICLE IS WASHED REGULARLY IN THE WINTER.

CORROSION WAS FOUND ON PASSENGER SIDE OF FRAME DURING 2020 STATE SAFETY INSPECTION CAUSING FAILURE OF SAID STATE INSPECTION. CORROSION WAS PREVIOUSLY FOUND ON DRIVER SIDE FRAME DURING 2018 STATE SAFETY INSPECTION AND WAS RECTIFIED BY BODY SHOP WELDER. VEHICLE IS GARAGED WHEN NOT IN USE.