TRACTION CONTROL SYSTEM MALFUNCTIONS INTERMITTENTLY WHILE DRIVING AROUND CURVES. SEVERAL TIMES WHILE DRIVING APPROXIMATELY 30-40 MILES PER HOUR ON A MOUNTAIN ROAD, THE ANTI SKID LIGHT ILLUMINATES WITHOUT WARNING ON A DRY PAVED ROAD WITH A SUBSEQUENT SUDDEN PULL TO THE RIGHT AND "GRINDING" NOISE. THIS HAS HAPPENED MULTIPLE TIME…
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TRACTION CONTROL SYSTEM MALFUNCTIONS INTERMITTENTLY WHILE DRIVING AROUND CURVES. SEVERAL TIMES WHILE DRIVING APPROXIMATELY 30-40 MILES PER HOUR ON A MOUNTAIN ROAD, THE ANTI SKID LIGHT ILLUMINATES WITHOUT WARNING ON A DRY PAVED ROAD WITH A SUBSEQUENT SUDDEN PULL TO THE RIGHT AND "GRINDING" NOISE. THIS HAS HAPPENED MULTIPLE TIMES WITHOUT WARNING. THE TOYOTA DEALER CAN NOT HELP, SINCE HE CAN NOT REPLICATE THE PROBLEM. THE LATEST OCCURRENCE PULLED THE VEHICLE ACROSS THE CENTER LINE INTO THE ONCOMING TRAFFIC LANE. (HAD THERE BEEN ONCOMING TRAFFIC THIS WOULD HAVE BEEN A SERIOUS ACCIDENT)
NHTSA ODI #10886135
76,500 miles · Jun 23, 2016
Suspension
FRAME IS RUSTING OUT
NHTSA ODI #10876064
138,000 miles · Feb 14, 2016
Power TrainSuspension
I TOOK MY VEHICLE IN FOR A ROUTINE OIL CHANGE RECENTLY AND THE TECHNICIAN SAID THAT I HAVE SOME MAJOR RUST ISSUES ON MY REAR AXLE AND DRIVETRAIN. HE SHOULD ME WHEN IT WAS ON THE LIFT. HE EXPLAINED TO ME THAT THE BOLT AND CLIP THAN HOLDS THE BRAKE LINE DOWN ON THE REAR DIFFERENTIAL HAD RUSTED AND BROKEN OFF OF THE DIFFERENTIAL CO…
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I TOOK MY VEHICLE IN FOR A ROUTINE OIL CHANGE RECENTLY AND THE TECHNICIAN SAID THAT I HAVE SOME MAJOR RUST ISSUES ON MY REAR AXLE AND DRIVETRAIN. HE SHOULD ME WHEN IT WAS ON THE LIFT. HE EXPLAINED TO ME THAT THE BOLT AND CLIP THAN HOLDS THE BRAKE LINE DOWN ON THE REAR DIFFERENTIAL HAD RUSTED AND BROKEN OFF OF THE DIFFERENTIAL COVER. THE REAR DIFFERENTIAL IS NOW LEAKING GEAR OIL. THE TECHNICIAN ADVISED ME THAT IT IS TOO RISKY TO ATTEMPT TO REPAIR AS IT MAY CAUSE THE ENTIRE DIFFERENTIAL TO BE DAMAGED AND THE WHOLE REAR AXLE WOULD NEED TO BE REPLACED. THE TECHNICIAN ALSO SAID THAT IT IS A RISK TO DRIVE THE VEHICLE AND IS POSSIBLY UNSAFE TO KEEP DRIVING. HE STATED THAT IT IS UNKNOWN HOW MUCH LONGER I WOULD BE ABLE TO DRIVE IT UNTIL THE REAR AXLE CEASES.
NHTSA ODI #10826027
250,000 miles · Nov 15, 2015
Suspension
I HAVE A 2002 TOYOTA 4 RUNNER THAT WAS TAKEN IN FOR YEARLY STATE INSPECTION AND THE TECHNICIAN INFORMED THAT THE FRAME IS ROTTED THROUGH. HE STATED THAT THE VEHICLE WAS UNSAFE TO DRIVE AND A REJECTION STICKER HAS BEEN PLACED ON THE VEHICLE. NOT SURE WHAT TO DO NOW. THE VEHICLE STILL LOOKS AND RUNS VERY WELL, BUT UNABLE TO DRI…
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I HAVE A 2002 TOYOTA 4 RUNNER THAT WAS TAKEN IN FOR YEARLY STATE INSPECTION AND THE TECHNICIAN INFORMED THAT THE FRAME IS ROTTED THROUGH. HE STATED THAT THE VEHICLE WAS UNSAFE TO DRIVE AND A REJECTION STICKER HAS BEEN PLACED ON THE VEHICLE. NOT SURE WHAT TO DO NOW. THE VEHICLE STILL LOOKS AND RUNS VERY WELL, BUT UNABLE TO DRIVE.
NHTSA ODI #10790501
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
100,500 miles · Sep 29, 2015
SuspensionUnknown Or Other
FRAME AND SOME SUSPENSION PARTS ARE VERY RUSTED, FRAME HAS HOLES AND IS BECOMING UNSAFE TO DRIVE. VEHICLE IS ONLY 13 YEARS OLD, ONLY 100100 MILES. PASSENGER SIDE FRONT SUSPENSION POP'S WHEN STRESSED IN CORNERING. WHEN AT IDLE, YOU CAN HEAR THE VIBRATION FROM RUST CHUNKS IN THE FRAME. ALL HEAT SHIELDS RUSTED. SKID PLATES ON …
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FRAME AND SOME SUSPENSION PARTS ARE VERY RUSTED, FRAME HAS HOLES AND IS BECOMING UNSAFE TO DRIVE. VEHICLE IS ONLY 13 YEARS OLD, ONLY 100100 MILES. PASSENGER SIDE FRONT SUSPENSION POP'S WHEN STRESSED IN CORNERING. WHEN AT IDLE, YOU CAN HEAR THE VIBRATION FROM RUST CHUNKS IN THE FRAME. ALL HEAT SHIELDS RUSTED. SKID PLATES ON FRONT AND FUEL TANK SO RUSTED MUST REMOVE. NOW NOTHING IS PROTECTING THE FUEL TANK.
NHTSA ODI #10778598
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
102,000 miles · Sep 14, 2015
SuspensionUnknown Or Other
AFTER BUYING THIS VEHICLE I WAS UNDERNEATH VEHICLE TO REPAIR A AXLE SEAL LEAKING AND FOUND EXTENSIVE FRAME RUST ON PASSENGER REAR OF FRAME. BY EXTENSIVE I MEAN THE FRAME WAS RUSTED COMPLETELY THROUGH! I HAVE LIVED IN OHIO ALL OF MY LIFE AND HAVE NEVER SEEN A VEHICLE WITH THIS MILEAGE AND OF THIS YEAR HAVE SUCH SEVERE FRAME RUS…
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AFTER BUYING THIS VEHICLE I WAS UNDERNEATH VEHICLE TO REPAIR A AXLE SEAL LEAKING AND FOUND EXTENSIVE FRAME RUST ON PASSENGER REAR OF FRAME. BY EXTENSIVE I MEAN THE FRAME WAS RUSTED COMPLETELY THROUGH! I HAVE LIVED IN OHIO ALL OF MY LIFE AND HAVE NEVER SEEN A VEHICLE WITH THIS MILEAGE AND OF THIS YEAR HAVE SUCH SEVERE FRAME RUST! AFTER FURTHER INSPECTION I NOTICED REAR END HOUSING WAS ALSO SEVERELY RUSTED. THE RUST ON THE FRAME IS SEVERELY PERFORATED AT POINT WHERE TRAILING ARM FOR THE REAR END ATTACHES TO THE FRAME! I WAS NOT AWARE OF THIS ISSUE BEFORE BUYING VEHICLE BUT AFTER SOME RESEARCH HAVE FOUND THAT THIS IS DEFINITELY A MANUFACTURER DEFECT OF SOME SORT! THESE VEHICLES ARE NOT SAFE TO DRIVE WITH THESE FRAMES IN THIS CONDITION AND TOYOTA IS AWARE OF THIS!
NHTSA ODI #10763756
115,000 miles · Apr 28, 2015
Suspension
THE FRAME ON THE 2002 4-RUNNER HAS COMPLETELY CORRODED AND CAUSED THE TOYOTA DEALERSHIP TO DEEM THE VEHICLE UNSAFE FOR DRIVING. EVEN THOUGH THIS A RECOGNIZED DESIGN FAILURE, TOYOTA REFUSES TO COVER THE COST OF REPLACEMENT. TOYOTA HAS RECALLED TUNDRA MODELS FOR THIS DEFECT, BUT REFUSES TO ACKNOWLEDGE THE 4-RUNNER DESIGN FLAW SIN…
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THE FRAME ON THE 2002 4-RUNNER HAS COMPLETELY CORRODED AND CAUSED THE TOYOTA DEALERSHIP TO DEEM THE VEHICLE UNSAFE FOR DRIVING. EVEN THOUGH THIS A RECOGNIZED DESIGN FAILURE, TOYOTA REFUSES TO COVER THE COST OF REPLACEMENT. TOYOTA HAS RECALLED TUNDRA MODELS FOR THIS DEFECT, BUT REFUSES TO ACKNOWLEDGE THE 4-RUNNER DESIGN FLAW SINCE IT WAS MANUFACTURED COMPLETELY AT THEIR HINO JAPAN PLANT. *TR
NHTSA ODI #10713384
194,000 miles · Apr 24, 2015
SteeringSuspension
VEHICLE BUCKED AND SWAYED AS REAR FRAME SEPARATED AT THE JOINT ON DRIVER SIDE WAS UNAWARE OF ISSUE BEFORE THIS TRIED TO FIND SWAY BAR ISSUE IT WAS SPOTTED AT A DISTANCE BY COWORKER. *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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