I VISITED A TOYOTA DEALERSHIP FOR ROUTINE MAINTENANCE (OIL CHANGE) AND INSPECTION OF 4 WHEEL DRIVE SYSTEM. AFTER THE VEHICLE WAS RAISED ON THE LIFT, THE SERVICE ADVISOR ASKED ME TO JOIN HIM AND THE SHOP MECHANIC IN THE SERVICE BAY WHERE I WAS SHOWN THAT THE FRAME / CHASSIS OF THE VEHICLE HAS RUSTED THE POINT WHERE IN THEIR OPIN…
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I VISITED A TOYOTA DEALERSHIP FOR ROUTINE MAINTENANCE (OIL CHANGE) AND INSPECTION OF 4 WHEEL DRIVE SYSTEM. AFTER THE VEHICLE WAS RAISED ON THE LIFT, THE SERVICE ADVISOR ASKED ME TO JOIN HIM AND THE SHOP MECHANIC IN THE SERVICE BAY WHERE I WAS SHOWN THAT THE FRAME / CHASSIS OF THE VEHICLE HAS RUSTED THE POINT WHERE IN THEIR OPINION IT WAS NO LONGER SAFE TO OPERATE. AFTER CLOSE INSPECTION, I HAD AGREED WITH THEIR ASSESSMENT. AN ONLINE SEARCH FOR A RECALL NOTICE WAS PERFORMED, BUT NONE WAS FOUND. OTHERWISE, THIS VEHICLE IS IN METICULOUS CONDITION WITH NO BODY DAMAGE OR RUST OR ANY MECHANICAL PROBLEMS.
NHTSA ODI #10819143
Mileage unknown · Jan 3, 2016
Structure
FRAME IS RUSTED THROUGH ON RIGHT SIDE FROM MIDDLE OF THE FRAME TO JUST OVER THE REAR AXEL. THERE ARE LARGE HOLES AND RUSTED SLOTS THAT ARE OVER 10 INCHES LONG DAMAGE STARTS BEFORE THE REAR SUSPENSHION SUPPORT AND CONTINUES TO THE OTHER SIDE AND THE SIDE WHERE THE RUST HAS CAUSED HOLES AND LONG SLOTS THE WHOLE FRAME CAN BE SQUEEZ…
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FRAME IS RUSTED THROUGH ON RIGHT SIDE FROM MIDDLE OF THE FRAME TO JUST OVER THE REAR AXEL. THERE ARE LARGE HOLES AND RUSTED SLOTS THAT ARE OVER 10 INCHES LONG DAMAGE STARTS BEFORE THE REAR SUSPENSHION SUPPORT AND CONTINUES TO THE OTHER SIDE AND THE SIDE WHERE THE RUST HAS CAUSED HOLES AND LONG SLOTS THE WHOLE FRAME CAN BE SQUEEZED EASILY WITH YOUR HAND.
NHTSA ODI #10817486
200,000 miles · Oct 26, 2015
Structure
FRAME RUSTED THROUGH. THERE IS A HOLE IN FRAME BECAUSE OF RUST.
NHTSA ODI #10786202
182,489 miles · Oct 3, 2015
StructureSuspension
VEHICLE WAS STATIONARY. WHILE REPLACING EXHAUST SYSTEM COMPONENTS. FOUND WHAT APPEARED TO BE MINOR RUST ON THE PASSENGER (RIGHT) SIDE REAR SUSPENSION MOUNT. FURTHER INVESTIGATION UNCOVERED A LARGER AREA OF RUST ALONG THE 3 WELDS ON THE INNER FRAME RAIL. CUT / GROUND THE METAL BACK TO GOOD METAL AND AM IN THE PROCESS OF PATCHING …
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VEHICLE WAS STATIONARY. WHILE REPLACING EXHAUST SYSTEM COMPONENTS. FOUND WHAT APPEARED TO BE MINOR RUST ON THE PASSENGER (RIGHT) SIDE REAR SUSPENSION MOUNT. FURTHER INVESTIGATION UNCOVERED A LARGER AREA OF RUST ALONG THE 3 WELDS ON THE INNER FRAME RAIL. CUT / GROUND THE METAL BACK TO GOOD METAL AND AM IN THE PROCESS OF PATCHING FOR MY YEARLY MAINE VEHICLE INSPECTION. EITHER TOYOTA HAS BUILT AN INFERIOR FRAME OR THE NEWER CHEMICALS BEING USED TO KEEP THE ROADS CLEAR IN THE WINTER TO BE THE CAUSE OF THIS RUST WHICH COULD CAUSE THE REAR SUSPENSION TO FAIL AT THIS POINT IN THE FRAME AND CAUSE A ACCIDENT.
NHTSA ODI #10779459
64,000 miles · Sep 17, 2015
StructureSuspension
TL* THE CONTACT OWNS A 2002 TOYOTA 4RUNNER. THE CONTACT STATED THAT THE REAR TRAILING ARM ON THE VEHICLE PREMATURELY DETERIORATED AND FRACTURED. THE VEHICLE WAS TOWED TO THE CONTACT'S RESIDENCE AND THEN TOWED TO AN INDEPENDENT MECHANIC. WHO DIAGNOSED THAT THE REAR END HOUSING AND AXLE DIFFERENTIAL NEEDED TO BE REPLACED. THE VEH…
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TL* THE CONTACT OWNS A 2002 TOYOTA 4RUNNER. THE CONTACT STATED THAT THE REAR TRAILING ARM ON THE VEHICLE PREMATURELY DETERIORATED AND FRACTURED. THE VEHICLE WAS TOWED TO THE CONTACT'S RESIDENCE AND THEN TOWED TO AN INDEPENDENT MECHANIC. WHO DIAGNOSED THAT THE REAR END HOUSING AND AXLE DIFFERENTIAL NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 64,000. UPDATED 11/20/15*LJ THE CONSUMER STATED THE VEHICLE SHOULD NOT HAVE TO BE REPAIRED AT THE OWNER'S EXPENSE. THE REAR DIFFERENTIAL HAD TO BE REPLACED. THE FRAME OF THE WAS ALSO BADLY RUSTED. UPDATED 2.3.16 *JS *CN
NHTSA ODI #10764478
Mileage unknown · Sep 9, 2015
Structure
FRAME RUSTED UNDER 4 RUNNER AND ON BUMPER TOLD BY PERSON WORKING ON SWAY BAR LINKS. STATED EXCESSIVE RUST ON FRAME AND REAR AXLE.
NHTSA ODI #10762726
180,000 miles · Sep 4, 2015
StructureUnknown Or Other
FRAME HAS EXCESSIVE RUST AND HAS HOLES IN PARTS OF IT. THE REST OF THE BODY AND INTERIOR ARE IN GREAT CONDITION. ENGINE RUNS WELL AND THERE ARE OTHERWISE NO MAJOR MECHANICAL ISSUES. UPON HAVING A MINOR REPAIR DONE, INSPECTION SHOWED THAT THE VEHICLE WAS UNSAFE TO DRIVE WITH THE FRAME IN THAT CONDITION AS IT IS ABOUT TO CRACK IN…
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FRAME HAS EXCESSIVE RUST AND HAS HOLES IN PARTS OF IT. THE REST OF THE BODY AND INTERIOR ARE IN GREAT CONDITION. ENGINE RUNS WELL AND THERE ARE OTHERWISE NO MAJOR MECHANICAL ISSUES. UPON HAVING A MINOR REPAIR DONE, INSPECTION SHOWED THAT THE VEHICLE WAS UNSAFE TO DRIVE WITH THE FRAME IN THAT CONDITION AS IT IS ABOUT TO CRACK IN HALF. THIS SEEMS TO BE PREMATURELY FAILING COMPARED TO THE REST OF THE VEHICLE.
NHTSA ODI #10761742
120,000 miles · May 14, 2015
SteeringStructure
TL* THE CONTACT OWNS A 2002 TOYOTA 4RUNNER. THE CONTACT INSPECTED THE VEHICLE AND DISCOVERED THAT THE ENTIRE REAR END OF THE FRAME COMPLETELY RUSTED. IN ADDITION, THE RACK AND PINION WAS FAULTY AND REPLACED BY AN INDEPENDENT MECHANIC. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILRUE MILEAGE WAS 120,000.
NHTSA ODI #10716412
60,000 miles · Mar 24, 2015
Power TrainStructureSuspension
THE FRAME IS RUSTING ALMOST IN TWO. LOOKS LIKE IT COULD BREAK ANY TIME. REAR AXEL IS ALSO VERY RUSTED WITH PIECES FALLING OFF. *TR
NHTSA ODI #10701395
99,000 miles · Mar 12, 2015
Structure
2002 TOYOTA 4 RUNNER SR5, 98,000 MILES. ALWAYS DEALER SERVICED. THIS WILL BE MY LAST STATE NYS INSPECTION AS I WILL BE UNABLE TO HAVE THE TRUCK INSPECTED IN 2015 DUE TO BODY FRAME ROT, NEED TO INCUR COSTS TO REPLACE BODY FRAME. TRUCK IS IN EXCELLENT CONDITION WITH THE EXCEPTION OF FRAME ROT. HAVE ALSO REPLACED THE BUMPER, T…
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2002 TOYOTA 4 RUNNER SR5, 98,000 MILES. ALWAYS DEALER SERVICED. THIS WILL BE MY LAST STATE NYS INSPECTION AS I WILL BE UNABLE TO HAVE THE TRUCK INSPECTED IN 2015 DUE TO BODY FRAME ROT, NEED TO INCUR COSTS TO REPLACE BODY FRAME. TRUCK IS IN EXCELLENT CONDITION WITH THE EXCEPTION OF FRAME ROT. HAVE ALSO REPLACED THE BUMPER, THE GAS TANK SHIELD AND HAVE BEEN TOLD FRONT OIL PAN SHIELD NEEDS REPLACING AS DEALER CAN NOT PERFORM OIL CHANGE, DUE TO THIS PROBLEM. I HAVE CONTACTED TOYOTA WAITING FOR A REPLY. *TR
ON CERTAIN SPORT UTILITY VEHICLES, DUE TO A MANUFACTURING ISSUE IN THE FRONT SUSPENSION LOWER BALL JOINT, THERE IS A POSSIBILITY THAT THE SURFACE OF THE BALL OF THE JOINT MAY HAVE BEEN SCRATCHED. THE BALL JOINT MAY EVENTUALLY EXPERIENCE EXCESSIVE WEAR AND LOOSENESS, RESULTING IN INCREASED STEERING EFFORT.
Consequence & remedy
Consequence: THE LOWER BALL JOINT MAY SEPARATE FROM THE KNUCKLE CAUSING LOSS OF STEERING CONTROL AND A CRASH COULD OCCUR.
Remedy: DEALERS WILL REPLACE THE FRONT SUSPENSION LOWER BALL JOINTS FREE OF CHARGE. THE RECALL BEGAN ON JULY 5, 2005. OWNERS MAY CONTACT TOYOTA AT 1-800-331-4331.
Model-level recall history does not show whether a particular VIN is affected or has received a repair. Check a VIN with NHTSA ↗
NHTSA investigations
1
DP18002 · 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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