Tap a category to read its complaints. One report may name several components.
When problems were reported
Mileage at the reported incident
40–25K
325–50K
1550–75K
1375–100K
57100–150K
54150K+
146 reports with mileage · 46 unknown
NHTSA’s mileage field refers to the reported incident, not necessarily the filing date. This shows report counts, not the likelihood of a failure.
What to inspect
Issues worth paying extra attention to based on owner reports.
Structure. Review the 88 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
Suspension. Review the 43 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
Power Train. Review the 29 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
NHTSA owner reports · September 18, 2026 snapshot.
12 crash reports2 fire reports9 injury reports
What owners actually said
192 reports
Mileage unknown · Dec 30, 2014
Structure
I WAS HAVING SERVICE WORK DONE AT TOYOTA ON MY 2002 TOYOTA 4RUNNER AND THE SERVICE MANAGER BROUGHT TO MY ATTENTION THE VEHICLE'S FRAME WAS RUSTING THROUGH, NEAR THE MUFFLER AND THE FRAME WOULD EVENTUALLY FAIL. HE SAID WAS A KNOWN DEFECT BUT NO RECALL HAD BEEN ISSUED. HE ALSO STATED THAT THE TOYOTA TACOMA HAD THE SAME PROBLEM AND…
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I WAS HAVING SERVICE WORK DONE AT TOYOTA ON MY 2002 TOYOTA 4RUNNER AND THE SERVICE MANAGER BROUGHT TO MY ATTENTION THE VEHICLE'S FRAME WAS RUSTING THROUGH, NEAR THE MUFFLER AND THE FRAME WOULD EVENTUALLY FAIL. HE SAID WAS A KNOWN DEFECT BUT NO RECALL HAD BEEN ISSUED. HE ALSO STATED THAT THE TOYOTA TACOMA HAD THE SAME PROBLEM AND A RECALL HAD BEEN ISSUED FOR THE TACOMA. THE RUST HOLES IN THE FRAME POSE A SERIOUS SAFETY ISSUE. THE SERVICE MANAGER SAID HE HAD SEEN OTHER 4RUNNERS WITH THE SAME ISSUE AND EVEN SUGGESTED TO THOSE OWNERS THAT THEIR VEHICLE WAS NOT SAFE TO DRIVE. *JS
NHTSA ODI #10669097
175,000 miles · Dec 23, 2014
Service BrakesVehicle Speed Control
VSC, TRAC OFF, ABS AND BRAKE LIGHTS CAME ON WHILE DRIVING. HIGH PITCHED BUZZER/ALARM STARTED AND REMAINED CONSTANT. BRAKES BECAME VERY HARD TO DEPRESS AND I LOST MOST BRAKING POWER. *TR
NHTSA ODI #10668016
158,000 miles · Dec 17, 2014
Power TrainStructure
FRAME AND REAR DIFFERENTIAL RUSTING OUT. *TR
NHTSA ODI #10666960
119,000 miles · Dec 11, 2014
Structure
TL* THE CONTACT OWNS A 2002 TOYOTA 4 RUNNER. WHILE DRIVING APPROXIMATELY 45 MPH, THE CONTACT LOST CONTROL OF THE VEHICLE. THE CONTACT HAD TO APPLY FORCE TO THE BRAKE PEDAL IN ORDER FOR THE VEHICLE TO COME TO A COMPLETE STOP. THE VEHICLE WAS TAKEN TO A DEALER, WHO DIAGNOSED THAT THE TRAILING ARM WAS CORRODED AND THAT THE ENTIRE F…
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TL* THE CONTACT OWNS A 2002 TOYOTA 4 RUNNER. WHILE DRIVING APPROXIMATELY 45 MPH, THE CONTACT LOST CONTROL OF THE VEHICLE. THE CONTACT HAD TO APPLY FORCE TO THE BRAKE PEDAL IN ORDER FOR THE VEHICLE TO COME TO A COMPLETE STOP. THE VEHICLE WAS TAKEN TO A DEALER, WHO DIAGNOSED THAT THE TRAILING ARM WAS CORRODED AND THAT THE ENTIRE FRAME NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS 119,000. THE VIN WAS UNAVAILABLE.
NHTSA ODI #10663710
Mileage unknown · Nov 26, 2014
Power Train
TL* THE CONTACT OWNS A 2002 TOYOTA 4RUNNER. THE CONTACT STATED THAT FLUID WAS LEAKING UNDER THE VEHICLE. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC. THE TECHNICIAN DIAGNOSED THAT THE REAR DIFFERENTIAL HOUSING WAS RUSTED, LEAKED FLUID INTERMITTENTLY AND THERE WERE MULTIPLE HOLES TO THE POINT THAT THE COMPONENT MAY FRACTURE.…
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TL* THE CONTACT OWNS A 2002 TOYOTA 4RUNNER. THE CONTACT STATED THAT FLUID WAS LEAKING UNDER THE VEHICLE. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC. THE TECHNICIAN DIAGNOSED THAT THE REAR DIFFERENTIAL HOUSING WAS RUSTED, LEAKED FLUID INTERMITTENTLY AND THERE WERE MULTIPLE HOLES TO THE POINT THAT THE COMPONENT MAY FRACTURE. THE REAR DIFFERENTIAL NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS NOT AVAILABLE.
NHTSA ODI #10661047
167,000 miles · Nov 23, 2014
StructureSuspension
EXTENSIVE RUST THRU ON DRIVERS SIDE OF FRAME, REAR SUSPENSION LINK RUSTED TO THE POINT WHERE COMPLETE FAILURE IN COMING SOON. LAST TWO FEET OF FRAME COMPLETELY GONE. DOUBT IT WILL PASS ANOTHER SAFETY INSPECTION WITHOUT SIGNIFICANT REPAIR. REAR DIFFERENTIAL RUSTED TO THE POINT GEAR OIL LEAKS. THIS IS COMMON ON ALL 4 RUNNERS…
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EXTENSIVE RUST THRU ON DRIVERS SIDE OF FRAME, REAR SUSPENSION LINK RUSTED TO THE POINT WHERE COMPLETE FAILURE IN COMING SOON. LAST TWO FEET OF FRAME COMPLETELY GONE. DOUBT IT WILL PASS ANOTHER SAFETY INSPECTION WITHOUT SIGNIFICANT REPAIR. REAR DIFFERENTIAL RUSTED TO THE POINT GEAR OIL LEAKS. THIS IS COMMON ON ALL 4 RUNNERS AND SHOULD BE RECALLED JUST LIKE THE TACOMAS. *TR
NHTSA ODI #10660383
112,000 miles · Nov 10, 2014
Power Train
REAR DIFFERENTIAL HAS RUSTED THROUGH, THE WHOLE THING HAS TO BE REPLACED BECAUSE THERE IS NO SEPARATE COVER THE REPAIR COST MAY BE HIGH. *TR
NHTSA ODI #10653785
86,000 miles · Nov 4, 2014
StructureSuspension
TL* THE CONTACT OWNS A 2002 TOYOTA 4RUNNER. THE CONTACT STATED THAT THE REAR AXLE WAS CORRODED AND CAUSED THE FRAME TO DETACH. THE VEHICLE WAS TAKEN TO A DEALER. THE TECHNICIAN DIAGNOSED THAT THE FRAME AND REAR END NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE APPROXIMATE …
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TL* THE CONTACT OWNS A 2002 TOYOTA 4RUNNER. THE CONTACT STATED THAT THE REAR AXLE WAS CORRODED AND CAUSED THE FRAME TO DETACH. THE VEHICLE WAS TAKEN TO A DEALER. THE TECHNICIAN DIAGNOSED THAT THE FRAME AND REAR END NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 86,000.
NHTSA ODI #10652416
139,000 miles · Sep 5, 2014
Fuel/propulsion SystemStructure
MY 2002 4RUNNER WAS PURCHASED BRAND NEW FROM TOYOTA IN NOVEMBER OF 2001. I LIVE IN NEW YORK SO IT DOES SNOW 2 OR 3 MONTHS OUT OF THE YEAR. IT HAS BEEN USED AS A SECOND VEHICLE TO PICK UP SUPPLIES AND THE LIKE, OTHERWISE IT IS RARELY USED. AT THIS TIME IT HAS APPROX. 139000 MILES. THE TRUCK WOULD NOT START AND I TOOK IT TO A MECH…
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MY 2002 4RUNNER WAS PURCHASED BRAND NEW FROM TOYOTA IN NOVEMBER OF 2001. I LIVE IN NEW YORK SO IT DOES SNOW 2 OR 3 MONTHS OUT OF THE YEAR. IT HAS BEEN USED AS A SECOND VEHICLE TO PICK UP SUPPLIES AND THE LIKE, OTHERWISE IT IS RARELY USED. AT THIS TIME IT HAS APPROX. 139000 MILES. THE TRUCK WOULD NOT START AND I TOOK IT TO A MECHANIC. I WAS TOLD THERE IS AN EXTREME AMOUNT OF RUST UNDER THE VEHICLE, THE UNDERCARRIAGE, THE FRAME, THE GAS TANK, ETC. THE PROBLEM IS THE FUEL PUMP BUT BECAUSE OF SO MUCH RUST, REMOVING THE GAS TANK TO CHANGE THE FUEL PUMP MAY CAUSE DAMAGE TO THE COMPONENTS CONNECTING THE TANK TO THE FRAME OF THE VEHICLE. IT IS A SHAME THAT TOYOTA SELLS A VEHICLE THAT MAY NEED TO BE JUNKED DUE TO THE AMOUNT OF RUST IT HAS. I UNDERSTAND THAT MANY OTHER OWNERS HAVE THE SAME PROBLEM WITH THE 4RUNNER AND SOMETHING SHOULD BE DONE. I BOUGHT A 1999 CAMRY BRAND NEW PRIOR TO THE 4RUNNER AND I HAD IT FOR 12 YEARS BEFORE GIVING IT TO A FRIEND WHO STILL DRIVES IT TO THIS DAY AND IT HAS NO RUST. THE 4RUNNER RUNS GREAT ALL OF THE YEARS I HAVE OWNED IT BUT I AM BEING TOLD BY MY MECHANIC THAT IT IS POSSIBLE THE BODY OF MY TRUCK COULD FALL FROM THE FRAME. AT 139000 MILES THIS SHOULD NOT BE HAPPENING. TOYOTA SHOULD OFFER SOME KIND OF REPAIR TO THESE ISSUES. MY TRUCK LOOKS ALMOST BRAND NEW EXCEPT FOR SOME RUST ON THE FRONT AND REAR BUMPERS AND NOW I MAY HAVE TO JUNK IT. *TR
NHTSA ODI #10631160
142,986 miles · Sep 1, 2014
EnginePower Train
4 WHEEL DRIVE WOULD NOT WORK. VCS LITES AND CHECK ENGINE LITES ON. CAR ENGINE FILLED WITH BLACK SMOKE AND WAS TOWED TO REPAIR SHOP. DETAILS: DROVE ON FREEWAY AND LOST TRACTION AND THAN ON SHOULDER WITH ABOVE PROBLEM. DIFFERENTIAL REPAIRED. TWO DAYS LATER LITES ON AGAIN AND OIL LEAK. *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
2002 Toyota 4RUNNER Problems, Complaints & Recalls | Skip That Year
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