NHTSA owner reports · September 18, 2026 snapshot.
Structure complaints
88 reportsClear category filter140,000 miles · Apr 14, 2019
StructureUnknown Or Other
WE PURCHASED A 4RUNNER FOR OUR 18 YEAR OLD DAUGHTER TO DRIVE THINKING IT WOULD BE SAFE, ESP IN MN. SHE WAS DRIVING HOME FROM COLLEGE (130 MILES) AND NOTICED IT HAD A BAD VIBRATION, ESPECIALLY OVER 40 MPH. IT WAS VERY DIFFICULT TO DRIVE. WE WERE OUT OF TOWN AND WHEN WE GOT BACK, BROUGHT IT TO THE SHOP, ONLY TO BE TOLD THE FRAM…
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WE PURCHASED A 4RUNNER FOR OUR 18 YEAR OLD DAUGHTER TO DRIVE THINKING IT WOULD BE SAFE, ESP IN MN. SHE WAS DRIVING HOME FROM COLLEGE (130 MILES) AND NOTICED IT HAD A BAD VIBRATION, ESPECIALLY OVER 40 MPH. IT WAS VERY DIFFICULT TO DRIVE. WE WERE OUT OF TOWN AND WHEN WE GOT BACK, BROUGHT IT TO THE SHOP, ONLY TO BE TOLD THE FRAME WAS RESPONDED BEYOND REPAIR (SEE PHOTOS). NOT ONLY DOES THAT SCARE ME FOR MY DAUGHTER, BUT SHE HAS BEEN DRIVING IT A FEW YEARS AND HAD FRIENDS AND OTHER FAMILY MEMBERS IN THE VEHICLE. THE VEHICLE HAS RELATIVELY LOW MILES FOR IT'S AGE AND BASED ON TOYOTAS REPUTATION OF LONGEVITY, WE NEVER EXPECTED THIS SORT OF ISSUE. WE'RE THANKFUL SHE WASN'T HURT, BUT ARE CONCERNED ABOUT OTHERS DRIVING A VEHICLE AND NOT KNOWING IT COULD LITERALLY BREAK IN HALF WHILE DRIVING DOWN THE ROAD!
NHTSA ODI #11196149
145,000 miles · Apr 8, 2019
Service BrakesStructure
THE FRAME OF THIS 4RUNNER HAS BEEN EXPERIENCING EXCESSIVE RUST SINCE THE TIME I GOT IT USED FROM A DEALER. ONCE THEIR UNDERCOATING WORE OFF, MY MECHANIC REPLACED RUSTED UP BRAKE LINES BACK ABOUT 9 YEARS AGO. HE SAID IT WAS BECAUSE THE FRAME WAS VERY RUSTY AND THEY DID A NEW RUST TREATMENT. FOR THE PAST FEW YEARS I HAVE BEEN B…
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THE FRAME OF THIS 4RUNNER HAS BEEN EXPERIENCING EXCESSIVE RUST SINCE THE TIME I GOT IT USED FROM A DEALER. ONCE THEIR UNDERCOATING WORE OFF, MY MECHANIC REPLACED RUSTED UP BRAKE LINES BACK ABOUT 9 YEARS AGO. HE SAID IT WAS BECAUSE THE FRAME WAS VERY RUSTY AND THEY DID A NEW RUST TREATMENT. FOR THE PAST FEW YEARS I HAVE BEEN BATTLING ISSUES RELATED TO THE FRAME. A PLATE WAS PUT IN TO STRENGTHEN AN AREA. IT ONLY HAS 164K ON IT, I REBUILT THE TRANSMISSION AT 125K, AND THE BODY IS IN GOOD SHAPE. JUST THAT THE RUST IS SPREADING EVERYWHERE UNDERNEATH. WE TRIED TO GET IT ADDRESSED IN THE PREVIOUS TOYOTA FRAME RECALL BUT IT WAS NOT FOR THIS AGE FOR WHATEVER REASON. EVERY REPAIR HAS BEEN MORE DIFFICULT DUE TO RUSTING BOLTS, MUFFLERS RUSTING EARLY, BRAKE LINES BUSTING DUE TO RUST, THE TOW HITCH RUSTED THROUGH. NOW THERE IS A GAPING HOLE IN THE REAR SIDE OF THE FRAME SUPPORTING THE CAB. AFTER BEING UNDER THE CAR TRYING TO SCRAPE RUST OFF, AND TO PUT SOME RUST RESTORE/PROTECTION, I SAW THE NEW HOLE AND GOT FED UP. SO I SEE YOU ARE NOW INVESTIGATING THIS YEAR 4RUNNER TO ADD TO THEIR RECALL. PLEASE...DO! SOMETHING SERIOUS COULD HAPPEN WHILE DRIVING IT AND IT WILL JUST STAY MOSTLY PARKED UNTIL THIS IS RESOLVED. BRAKE FAILURE WHEN MY SON WAS DRIVING WAS ALREADY SCARY ENOUGH. THANK YOU.
NHTSA ODI #11194759
215,000 miles · Apr 1, 2019
Structure
VEHICLE FRAME HAS CORRODED, FRACTURED ESPECIALLY ON PASSENGER REAR OF VEHICLE. MANY HOLES ALONG FRAME. WAS HEARING LOUD THUNKING IN REAR OF VEHICLE TOOK IT IN FOR A VISUAL INSPECTION AND FOUND THE ISSUE.
NHTSA ODI #11193162
199,432 miles · Mar 17, 2019
SteeringStructureSuspension
I WAS DOING AN OIL CHANGE AND NOTICED THAT THE FRAME WAS RUSTED VERY BADLY . I THINK THAT THERE SHOULD BE A RECALL ON THIS MODEL 3RD GEN 4RUNNER (1999-2002)THIS IS THE SAME FRAME AS THE TRUCK THAT WAS RECALLED ,SO THIS SHOULD BE INCLUDED .IF THIS FRAME BREAKS IT WILL HURT OR KILL SOME ONE .
NHTSA ODI #11187330
158,000 miles · Mar 10, 2019
EngineSteeringStructure
FIRST, THE MOTOR BLEW FOR NO REASON AT 152,000 MILES. I REBUILT THE CAR AND HAD A NEW MOTOR PUT IN. I WAS NOT AWARE OF THE RUSTING FRAME ISSUE, HOWEVER, AFTER DRIVING THE VEHICLE WITH A LOVELY NEW REBUILT MOTOR FOR ABOUT ONE YEAR, THE FRAME ROTTED BEYOND REPAIR CAUSING THE POWER STEERING TO GO OUT. I DON'T DRIVE MUCH, SO THER…
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FIRST, THE MOTOR BLEW FOR NO REASON AT 152,000 MILES. I REBUILT THE CAR AND HAD A NEW MOTOR PUT IN. I WAS NOT AWARE OF THE RUSTING FRAME ISSUE, HOWEVER, AFTER DRIVING THE VEHICLE WITH A LOVELY NEW REBUILT MOTOR FOR ABOUT ONE YEAR, THE FRAME ROTTED BEYOND REPAIR CAUSING THE POWER STEERING TO GO OUT. I DON'T DRIVE MUCH, SO THERE WAS NO EXCESSIVE EXPOSURE TO SALT. THE CAR WAS PARKED IN MY DRIVEWAY. IT WAS AN EXCEPTIONALLY COLD DAY. I STARTED THE VEHICLE AND FOUND THE POWER STEERING FLUID HAD FROZEN AND LOST ALL THE FLUID AS A RESULT OF THE STEERING RACK BEING RUSTED AND WEAKENED. THE REPAIR SHOP TOLD ME THAT THE FRAME AND ROCKER PANELS ARE SEVERELY COMPROMISED TOO BADLY TO BOTHER FIXING THE STEERING RACK. THE CAR IS NOT SAFE TO DRIVE.
NHTSA ODI #11185623
Mileage unknown · Feb 24, 2019
Structure
I HAVE SEEN CLASSI. CARS FROM THE 60S WITH FRAMES IN BETTER SHAPE THAN MY 4RUNNER. THE REAR CONTROL ARMS BRACKETS ARE CLOSE TO DETACHING FROM THE FRAME. RUST IS EATING THE BACK HALF OF MY FRAME. THE FRAME RAILS ARE COMPLETELY RUSTED THROUGH AND WILL SOON NEED REPLACING. THERE ARE NUMEROUS BOLTS AND HARDWARE THAT CAN NO LONGE…
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I HAVE SEEN CLASSI. CARS FROM THE 60S WITH FRAMES IN BETTER SHAPE THAN MY 4RUNNER. THE REAR CONTROL ARMS BRACKETS ARE CLOSE TO DETACHING FROM THE FRAME. RUST IS EATING THE BACK HALF OF MY FRAME. THE FRAME RAILS ARE COMPLETELY RUSTED THROUGH AND WILL SOON NEED REPLACING. THERE ARE NUMEROUS BOLTS AND HARDWARE THAT CAN NO LONGER BE USED DUE TO RUST. THE FILL PLUG ON THE REAR DIFFERENTIAL HAS RUSTED AWAY AS WELL. THE QUALITY OF THIS STEEL IS ABSOLUTELY HORRIBLE. TOYOTA SHOULD BE ASHAMED OF A VEHICLE THAT HAS PROBLEMS LIKE THIS. I HAVE NEVER SEEN RUST THIS BAD ON A FRAME BEFORE.
NHTSA ODI #11182218
100,000 miles · Feb 17, 2019
Structure
EXCESSIVE RUST ON FRAME SINCE 2008. TOYOTA REFUSED TO ADDRESS AFTER FILING FORMAL COMPLAINT. I BELIEVE LIKE TRUCKS OF SAME YEAR THAT HAD FRAMES REPLACED, 4 RUNNERS SHOULD BE INCLUDED
NHTSA ODI #11180640
120,000 miles · Feb 14, 2019
Structure
AT A STOP LIGHT, WENT TO DRIVE HEARD LOAD POP CLANK. VEHICLE STARTED SHAKING AND DRIVING FUNNY. LOOKED UNDER CAR AND MY CONTROL ARM ( THAT STABILIZES MY AXEL ) MOUNT RUSTED OFF. MY ENTIRE UNDER CARRIAGE IS RUSTED OUT. THE CONTROL ARM SHIFTED
NHTSA ODI #11180132
155,000 miles · Nov 27, 2018
Structure
EXCESSIVE RUST ON FRAME. RUSTING FROM THE INSIDE OUT, ON PASSENGER SIDE NEAR MUFFLER, BY REAR SUSPENSION MOUNTS. RUSTED ALL THE WAY THROUGH ON THE INSIDE OF THE FRAME. LIKELY RUSTED IN OTHER PARTS THAT ARE NOT VISIBLE.
NHTSA ODI #11154372
180,000 miles · Nov 19, 2018
Structure
MY 2002 TOYOTA 4RUNNER HAS EXCESSIVE RUST ON THE FRAME TO THE POINT THAT IT HAS BEEN DEEMED BY MY LOCAL TOYOTA DEALERSHIP AS "UNSAFE TO DRIVE." IT ONLY HAS 180,000 MILES ON IT, THE RUST SHOULD NOT BE THIS EXTENSIVE.
NHTSA ODI #11152575
NHTSA investigations
1DP18002 · Frame Corrosion
Opened Aug 17, 2018 · Closed Mar 18, 2022
Status: closed (inferred from source dates) · Structure:frame And Members
On August 7, 2018, the Office of Defects Investigation (ODI) received a defect petition from Mr. Gary Weinreich alleging premature frame corrosion failure in model year (MY) 2002 - 2006 Toyota 4Runner vehicles. The petitioner based his request upon a corrosion-related front suspension failure he experienced in his MY 2005 Toyota 4Runner, a class action lawsuit settlement involving other Toyota products, and other complaints of underbody corrosion in Toyota 4Runner vehicles that he found in NHTSA?s online complaint database. The petitioner submitted a complaint to NHTSA documenting his experience (NHTSA ID 11098055). On August 17, 2018, ODI opened DP18-002 to evaluate the petitioner?s request. ODI?s evaluation included information provided by the petitioner regarding his vehicle, facts related to the class action lawsuit cited by the petitioner, and consumer complaint data received by NHTSA regarding underbody corrosion in third and fourth-generation Toyota 4Runner vehicles.The undercarriage of the petitioner?s vehicle exhibited severe corrosion damage indicative of seawater immersion. The vehicle?s service history shows that concerns with underbody corrosion were first noted by a Toyota dealer in a multi-point vehicle inspection performed on April 28, 2011. The invoice for that inspection noted ?severe and excessive amount of rust on the undercarriage and on the drive shaft transmission.? Two years later, on October 21, 2013, another multi-point inspection by a Toyota dealer observed further progression of underbody corrosion damage, noting: ?rust on shocks/struts and other components,? ?rust on exhaust system,? ?both splash shields severely rusted,? and ?undercarriage very rusty.? On July 17, 2017, approximately 10 months prior to experiencing the suspension failure incident, an independent repair facility performing routine oil change and brake maintenance informed the Petitioner of a concern with ?excessive frame corrosion? on his vehicle. The service history, severe general corrosion damage, failure age, and environment do not support the petitioner?s allegation of premature corrosion failure.ODI?s analysis of NHTSA complaint data identified fifteen incidents of front lower control arm failure in fourth-generation Toyota 4Runner sport utility vehicles. Two of the failures, including the petitioner?s vehicle, involve vehicles operated in ocean front communities with continuous exposure to aerosolized marine salts and potential exposure to seawater immersion. The remaining thirteen failures all involved vehicles owned or previously registered in states with the greatest use of deicing salts to treat road surfaces in winter months (?Salt states?). On average, the front lower control arm failures occurred after 13.1 years in service in highly corrosive environments. The failure ages and environments do not support the petitioner?s allegation of premature corrosion failure. NHTSA is authorized to issue an order requiring notification and remedy of a defect if the Agency?s investigation shows a defect in design, construction, or performance of a motor vehicle that presents an unreasonable risk to safety. 49 U.S.C. ?? 30102(a)(9), 30118. Since the information before the Agency is not indicative of a vehicle-based defect, it is unlikely that any investigation opened because of granting this petition would result in an order concerning the notification and remedy of a safety-related defect. Therefore, upon full consideration of the information presented in the petition and the potential risks to safety, the petition is denied. The denial of this petition does not foreclose the Agency from taking further action if warranted or the p
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