2004 Toyota 4Runner complaints

Extreme Rusting on the frame undercarriage of the vehicle. Our mechanic found it today - said it must have been rusting for years & that this is a common problem with 03 - 05 Toyota 4Runners.

The chassis is completely rusted/rotten, 1" Holes throughout the chassis and was told that it won't pass inspection.

Unaware of frame rusting issues to vehicle.. Observed rust through carpet on driver side. Upon research safety is a concern. Due to high volume of this type of issuing occurring a safety recall should be issued. It was not verbalized at time of purchase the make and model of vehicle have these type of issues. Especially, when this issues had been occurring prior to purchase of this vehicle.

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 c

The right rear control arm mount completely rusted away from the frame. Causing it to start fish-tailing out of control. Also there are other mounts that have rusted through. Like for instance, the gas tank strap mounted to the frame. There are also more areas of the frame that are rusting through. I'm just glad that I was the only one in the vehicle and going slow enough to not cause an accident. I then took it to an auto repair shop and they informed me that the frame on my vehicle has many problem areas of being rusted through. I have attached some photos of the problem areas taken from the repair shop.

2004 Toyota 4 runner frame is corroded so bad and dealer mechanic thinks it is a default of manufacturer and suggested I file a complaint with you. He said many Toyota 4 runners having same issue and it is a safety hazzard.

The frame is rusted through on this 4Runner. Same frame as the tacomas that were recalled and I’m wondering why Toyota wouldn’t recall THE SAME EXACT FRAME WITH MAJOR RUST ISSUES on a different platform. This truck is not abused so it’s very frustrating to see it falling apart at the frame when everything else is intact and solid. The rot on this frame is inevitable. I’m going to be very upset if I have to pay out of my own pocket for something that should be 100% covered under recall. This is a huge safety hazard and could lead to serious injury or death.

Vehicle failed inspection due to hole in frame-- 08/14/20-- had to cover repairs--under body has severe frame damage from rust--toyota recalled and replaced truck frames from bad steel on 2004 tacomas but not to the 2004 4runners

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.

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).

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.

Under body has severe frame damage from rust.

The frame of the vehicle has rusted so badly the Toyota Dealer I have taken to for diagnosis and repairs refuses to put the vehicle on their lift to inspect or work on the underside of the car for fear of the safety of their workers. This is not a new problem for Toyota because they have lost a civil suit for premature rusting of the frames on other truck models. I took my 4Runner to a frame repair shop and got an estimate. I don't have the funds to do the repair. If the repairs were not made I could continue to drive it until the frame breaks I was told. When the frame breaks it's indeterminable, how many individuals could be injured? My hope when the frame breaks I don't lose control so I won't be killed or severely injured and any others that could be involved in the accident don't get harmed either. There has been a class-action lawsuit initiated where my 4Runner would be included in this suit. Toyota needs to be held accountable for a poorly designed and manufactured frame. I demand Toyota replace/repair the frame on my 4Runner so that it can be safely driven to the end of life of the engine and transmission before persons are harmed from a frame failure. Inver Grove Toyota first informed me the frame had holes rusted in it on November 19, 2019. Then, on Dec 20, 2019, they informed me it was unsafe to lift. I can supply copies of 3 repair invoices where the dealer made note of the corroded frame.

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.

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

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.

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

Side curtain shield airbags.

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.

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

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!

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 privatel

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.

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.

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 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

Last year the frame showed rust and holes and was rejected by the inspector. We were able to get the worst hole patched and it passed inspection. I am afraid the car might be unsafe.

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.

On April 14, 2019, I was informed by an auto repair shop that my 2004 Toyota 4Runner showed signs of excessive rusting on the front end of the frame at the bumper and radiator support. The repair shop owner/mechanic indicated the bumper may eventually fall off. At the time, the odometer reading was only 117,834 miles. On June 22, 2021, I took the truck in to the Toyota dealer where I purchased it to have the regular oil change done and requested that they inspect the frame during the routine "Multi-Point Inspection." On this visit to the Toyota dealer, the truck's odometer reading was 141,595. The mechanic pointed out the more severe areas of rusting, which included the "Front right bumper support crumple zone area, also right side top under pass front seat area very thin." He indicated that the left side of the frame, although not as advanced as the right side, was also rusting, because water from wet roadways accumulates within the frame and does not drain. I was not able to take photos of the top under pass due to lack of access. However, the mechanic had me run my fingers along the top of the frame. The frame was so corroded that it was crumbling, and my fingers went right through the frame. Some areas already had holes from the corrosion. I have included both the repair shop and Toyota dealer's observation reports as well as the photos of the front end of the frame and the right side under pass. It was not possible to take photos of the top of the right side under pass,

On April 17, 2019, I was informed by P.R. Auto Repair that my 2004 Toyota 4Runner showed signs of excessive rusting on the front end of the frame at the bumper support and radiator support. This observation was noted by the auto repair shop's owner. It is important to point out that my truck had only 117,834 miles on its odometer and should not already have had such a serious rusting problem. My truck was in for replacement of rear pads and rotors and was on a lift when the problem was noted. At the time the problem was being pointed out to me, a portion of the rusted metal in that area came right off. I was told that eventually the bumper could fall off and potentially lead to increased more dangerous problems. I have taken my 4Runner to A-1 Toyota where I purchased the vehicle for the regularly scheduled oil changes. "A-1 Toyota Quality Vehicle Inspections" were conducted each time with issues that required further attention noted in the report, but the rusting problem has never been included in the reports or pointed out to me. The truck now has just over 141,240 miles on its odometer and the corrosion problem has become significantly worse and my safety and the safety of others has become a growing concern to me. I have included a scanned copy of the April 19, 2019 invoice/receipt from the P.R. Auto Repair shop. The observation of the problem is noted under the Instructions section. I have also included two photos (one of the left side view and one of the right side view)

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.

THE ORIGINAL FRAME ON OUR CAR IS ALMOST COMPLETELY RUSTED. THERE ARE HOLES IN THE FRAME AND COMPLETE CORROSION ALONG THE SIDE BEAMS. THIS IS A HUGE SAFETY HAZARD WHILE DRIVING. THERE IS SO MUCH RUST ON THE UNDERBODY. ALL PARTS ARE COMPLETELY STOCK AND ORIGINAL. THIS SHOULD NOT BE A PROCESS WE HAVE TO PAY FOR AS IT IS A MAJOR SAFETY CONCERN THAT TOYOTA IS COMPLETELY OVERLOOKING. THE HOLES IN THE FRAME ARE ABOUT A BASEBALL SIZE WHOLE. I HAVE TAKEN IT TO OVER THREE MECHANICS AND A BODY SHOP RECOMMENDED FROM TOYOTA AND EACH OF THEM SAID THE FRAME IS ALMOST ENTIRELY UNSAFE.

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

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.

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.

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

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.

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.

VEHICLE FRAME HAS RUSTED COMPLETELY THROUGH IN CERTAIN AREAS - STRUCTURE AND SAFETY IS COMPROMISED .... NORMAL DRIVING & CARE ENVIRONMENT BUT APPEARS FRAME HAS ACCELERATED DETERIORATION, WHILE ALL OTHER AREAS (BODY PANELS, ALL OTHER COMPONENTS) ARE IN EXCELLENT CONDITION - SEEING THIS IS A KNOWN TOYOTA ISSUE ON SAME MODELS AND SIMILAR MODELS OF SAME PRODUCTION YEARS

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.