2004 Toyota 4Runner Suspension Problems

What component or system failed or malfunctioned, and is it available for inspection upon request? Response: Frame, Suspension, Airbags / Yes it is available for inspection. How was your safety or the safety of others put at risk? Response: Safety was put at risk due to frame & suspension failure due to severe rust. Also due to failure of deployment of AirBags. Rusted Frame Failure subsequently caused safety of Injured Party and other motorists to be at risk due to the Injured Party’s 4Runner to dart across oncoming lane of traffic with no warning other than a swaying motion felt immediately before losing control. Once the Injured Party lost control of the 4Runner it crossed into oncoming traffic, progressing into the drainage ditch on the oncoming traffic side of highway. Once the 4Runner impacted the drainage ditch at a 90° angle, the 4Runners momentum dispersed by causing the 4Runner to overturn 3 times landing on its wheels in the adjoining field. Has the problem been reproduced or confirmed by a dealer or independent service center? Repaonse: Independent Service Center has confirmed the problem with the Rusted Frame, Rusted Suspension, and Air Bag failure. Has the vehicle or component been inspected by the manufacturer, police, insurance representatives or others? Response : Yes Were there any warning lamps, messages or other symptoms of the problem prior to the failure, and when did they first appear? Repaint: No warning lamps prior to failure. Symptoms indicative of failure were an unknown minor swaying sensation while driving. Injured party was under the impression that there may have been a tire low on air, which was discovered to be incorrect later.

I recently bought a 2004 Toyota 4 Runner and the frame of the vehicle has significant corrosion to the extent of holes, weld failures and more. I've never seen frame rust so bad on a vehicle like this. I'm a little uneasy about the safety of this situation. I think Toyota should replace the frame or give a good discount on the part and labor. I hope someone can help me out with this concern.

Cars frame is rotting out to the point it is not safe to drive. I was told being in a collision could cause catastrophic failure and the car is just turning 20 years old with 125,000 miles. Can’t get my money back and the car is otherwise is excellent condition.

Frame is severely rusted and has holes started at 40k miles

UNKNOWN: Excessive frame rust. frame is excessively rusting to the point where the brakes and suspensions is connected to the frame has been compromised. brake lines rusted to the point of failure, thus almost causing a wreck. Vehicle is now parked due to safety concerns involving the excessive rusting that is happening to the frame and any components that is attached to the frame.

Excessive frame rusting. There are holes in the frame from rusting. At this point in time there isn’t anything I can do about the issues. Frame is unrepairable.

Frame of this vehicle completely rusted through. Holes on passenger side right where the front door ends. Hole is approx 12" long. Frame also has a hole in the left front core support. Advised that the vehicle is no longer safe to drive by my Toyota Dealer and personal mechanic. . There were no indications of this until a few weeks ago when the gas tank strap had come off and the gas tank was leaning. When inspected, it was found the frame was in disrepair.

Entire frame of the vehicle is rotten with rust and holes. This vehicle has been inspected by McDaniel Toyota, Marion, OH 43302 and the damage was confirmed. I have been and must continue to drive this vehicle even though the dealership did not recommend it. No evidence of the extent of the rust and damage was not noticed until October 2023 when a strap on the gas tank came loose. Upon further inspection, he noticed the holes and rust all over the frame. Reported to Toyota because other 2004 Models were recalled for this issue. They were of no assistance.

Frame rusted through on left rear of vehicle were suspension parts are attached.

Frame is falling apart rusted right out unsafe to drive a truck I'm making payments on.

The frame is damaged from excessive corrosion. The rear cross member that supports the trailer hitch and rear bumper is almost non-existent, which could result in the loss of the trailer being towed, and it will reduce the truck's rear impact resistance. The front right lower control arm has a 2'" x 3/8" lateral hole from corrosion, which could result in a catastrophic failure of the right front suspension system. The longitudinal frame members are compromised by corrosion which has penetrated through the steel in various locations. The front cross-frame member that supports the radiator is severely corroded. The frame to body mounts are showing signs of excessive corrosion which could result in the separation of the the body from the frame in an accident.

We took our 2004 4Runner for annual vehicle inspection and the service provider told us the vehicle would not pass safety inspection due to the excessive rusting on the steel frame and the suspension of the vehicle. Welding and patchwork will not fix this issue. My husband depends on this vehicle to work. The attached pictures give a small window into the extent of the damage. There is no current recall for this vehicle and year, but similar Toyota trucks from the same time frame have been recalled for the same exact issue. The entire frame needs to be replaced or worst case scenario, the vehicle is no longer usable. Toyota needs to remedy this issue for their loyal customers immediately.

I bought my 2004 Toyota 4runner Sport edition as a new car, and have been the sole owner of the vehicle. I have taken good care of it the entire time. Regular car washes, service maintenance and necessary repairs over time. I recently had my 4runner in for repairs and spent a considerable amount of money, over $6,000 in anticipation of driving it for many more years. Following the repairs I was told by the mechanic that the frame was EXTREMELY rusted and that the entire frame would need to be replaced. There are large holes rusted through in many areas of the frame and a tremendous amount of rust over the entire frame. Rusted Pieces of the frame have fallen off. I fear for the safety of my family and me if I were to drive the vehicle at all. I have barely driven it since learning of the dangerous condition of the frame. I've limited any driving at all to my immediate area, and have driven very carefully and slowly, as I am extremely concerned that there might be a catastrophic failure of the frame while driving and I may be injured or killed, or worse....the vehicle might cause harm or death to another person. I am now basically without a vehicle and have been forced to rely on my daughter's car, leaving the family with only one vehicle. This is a major failure of the vehicle. I can provide photos and video at your request. Toyota must be held accountable for the failure of this frame. The vehicle is now useless. I expect Toyota to rectify this situation immediately. Please contact me as soon as possible. Thank you. [XXX] INFORMATION Redacted PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6).

My Car was inspected by a Virginia Inspection Station and was cited for significant rust holes in the frame which have to be repaired. The frame should not have such significant rust that it needs to be fixed or it will be a hazard on the road. Based on other litigation around Toyota fames from this period of time is seems that this is a systemic issue and should be made to provide a recall based on the safety risk that is present with a frame failure as noted in previous class-action lawsuits. The Brian Warner et al. v. Toyota Motor Sales, U.S.A., Inc., Class Action Settlement (UNITED STATES DISTRICT COURT FOR THE CENTRAL DISTRICT OF CALIFORNIA Case No. 2:15-cv-02171-FMO-FFM) is a perfect example of the risk to the public if this is not corrected.

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!

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.