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2002 Toyota 4RUNNER

Owner reports · Recalls · Investigations

More warning signs than most 4RUNNER years

Owner complaints for the 2002 Toyota 4RUNNER are substantially higher than the model-year median of 58.

About this comparison →

When problems were reported

Mileage at the reported incident

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
106,000 miles · Jul 27, 2014
Suspension

RUST PERFORATION IN RIGHT SIDE REAR FRAME RAIL ACROSS FROM FUEL TANK INBOARD SIDE. I UNDERSTAND TOYOTA HAS ALREADY RECALLED THE TACOMA (SAME YEAR) FOR THE SAME ISSUES HOWEVER HAS NOT RECALLED THE 4RUNNER. CAR WILL NOT PASS INSPECTION NOR CAN DEALER REPAIR. *JS

NHTSA ODI #10616666

80,000 miles · Jul 15, 2014
Air BagsCrashInjury

TL* THE CONTACT OWNS A 2002 TOYOTA 4RUNNER. THE CONTACT STATED THAT WHILE DRIVING AT 30 MPH, SHE CRASHED INTO A LIGHT POLE AND THE VEHICLE FLIPPED OVER THREE TIMES. THE AIR BAGS FAILED TO DEPLOY. A POLICE REPORT WAS FILED. THE CONTACT SUSTAINED A HEAD INJURY, A BROKEN ARM, AND SUSTAINED CUTS ON HER LEGS FROM THE BROKEN GLASS THA…

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TL* THE CONTACT OWNS A 2002 TOYOTA 4RUNNER. THE CONTACT STATED THAT WHILE DRIVING AT 30 MPH, SHE CRASHED INTO A LIGHT POLE AND THE VEHICLE FLIPPED OVER THREE TIMES. THE AIR BAGS FAILED TO DEPLOY. A POLICE REPORT WAS FILED. THE CONTACT SUSTAINED A HEAD INJURY, A BROKEN ARM, AND SUSTAINED CUTS ON HER LEGS FROM THE BROKEN GLASS THAT WERE STITCHED. THE CONTACT REQUIRED MEDICAL ATTENTION. THE VEHICLE WAS TOWED AND DECLARED TOTALED. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 80,000. THE VIN WAS NOT AVAILABLE.

NHTSA ODI #10610807

50 miles · Jul 14, 2014
Engine

I WAS TRYING TO PASS A CAR DOING A LITTLE OVER 55 MPH AND HEARD A LOUD BANG NOISE. I PULLED OVER AND STOP THE AS AS QUICKLY AS POSSIBLE. THE OIL LIGHT CAME ON AND THERE WAS OIL WAS POURING OUT FROM UNDERNEATH THE MOTOR. THE OIL SERVICE WAS KEPT UP TO DATE AND WAS JUST CHANGED. THE CAR WAS TOWED AND THE ENGINE HAD THROWN A RO…

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I WAS TRYING TO PASS A CAR DOING A LITTLE OVER 55 MPH AND HEARD A LOUD BANG NOISE. I PULLED OVER AND STOP THE AS AS QUICKLY AS POSSIBLE. THE OIL LIGHT CAME ON AND THERE WAS OIL WAS POURING OUT FROM UNDERNEATH THE MOTOR. THE OIL SERVICE WAS KEPT UP TO DATE AND WAS JUST CHANGED. THE CAR WAS TOWED AND THE ENGINE HAD THROWN A ROD. MOTOR NEEDED TO BE REPLACE. (AFTER DOING SOME RESEARCH THIS SEEMS TO BE A PROBLEM WITH 4 RUNNER ENGINES WHEN THEY REACH 75000 MLES OR MORE. I AM NOT ALONE IN THIS PROBLEM.) I WAS LUCKY THAT I DIDN'T GET INTO AN ACCIDENT AND THAT I WASN'T ON THE EXPRESSWAY IN CHICAGO. I HAVE EMAILED TOYOTA. *TR

NHTSA ODI #10610432

Mileage unknown · May 28, 2014
Structure

THERE IS EXCESSIVE RUST ON THE FRAME RAILS WHICH SUPPORT THE BODY OF THE VEHICLE THUS WEAKENING THE CRITICAL SUPPORTIVE COMPONENTS. THIS CREATES A POSSIBLE DANGEROUS SITUATION WHICH MAY GO UNNOTICED UNTIL FAILURE OCCURS. THIS HAS BEEN A COMMON PROBLEM WITH OTHER TOYOTA VEHICLES AND SHOULD BE ADDRESSED FOR THE 4RUNNERS. *TR

NHTSA ODI #10594702

112,109 miles · Mar 15, 2014
Engine And Engine CoolingPower TrainStructure

I FILED A NHTSA COMPLAINT (ODI NUMBER 10569206 WAS ASSIGNED) ON 13 MARCH 2014 ABOUT THIS VEHICLE. ON 14 MARCH 2014, I TOOK MY 4RUNNER TO MY LOCAL TOYOTA DEALERSHIP AFTER CONTACTING TOYOTA CUSTOMER SERVICE AND LOGGING A COMPLAINT ( CASE NUMBER [XXX] ) WITH THEM ON THE 14TH OF MARCH 2014 AT THEIR OFFICE IN CALIFORNIA AND THE CUST…

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I FILED A NHTSA COMPLAINT (ODI NUMBER 10569206 WAS ASSIGNED) ON 13 MARCH 2014 ABOUT THIS VEHICLE. ON 14 MARCH 2014, I TOOK MY 4RUNNER TO MY LOCAL TOYOTA DEALERSHIP AFTER CONTACTING TOYOTA CUSTOMER SERVICE AND LOGGING A COMPLAINT ( CASE NUMBER [XXX] ) WITH THEM ON THE 14TH OF MARCH 2014 AT THEIR OFFICE IN CALIFORNIA AND THE CUSTOMER SERVICE REP TELLING ME DOCUMENTATION OF THE ISSUE AT MY DEALERSHIP WOULD HELP ME. THIS VEHICLE WAS BOUGHT IN NY AND REMAINED UP NORTH FOR 10 YEARS AND ACCORDING TO EMERSON TOYOTA AUBURN, ME RECORDS AT 85,199 MILES ON 07/11/2012. SERVICE ADVISER, [XXX] CONDITION1 AT 85,199 MILES . USED CAR PREP. VEHICLE BEING WHOLESALED PER RICH. NEEDS ENGINE LIGHT ON, A/C INOP, REAR AXLE HOUSING VERY RUSTED AND CRACKED, HOOD LATCH INOP, RADIATOR LEAKING, FRAME IS SOFT. IT HAD 85,404 MILES WHEN IT CAME TO FLORIDA ON 07 SEPTEMBER 2012 MY 2002 TOYOTA 4RUNNER SR5 WITH ONLY 112109 MILES AT COGGIN TOYOTA AT THE AVENUES DEALERSHIP ON PHILIPS HWY IN JACKSONVILLE, FLORIDA AT 12:20PM ON 14 MARCH 2014 MY COMPLAINT AT THE DEALERSHIP ON 14 MARCH 20014 AT 12:20.........CUSTOMER STATES REAR SUBFRAME IS RUSTED. CHECK AND ADVISE. THEIR FINDINGS AT 12:55PM ON 14 MARCH 2014... CASE NUMBER [XXX], FOUND SEVERE FRAME RUST, HOLES IN FRAME ON RIGHT SIDE, HOLES RUSTED THROUGH FRAME BY GAS TANK ON LEFT SIDE.HOLES RUSTED THROUGH GAS TANK AND LEAKING FUEL. UPPER REAR TRACK BAR BRACKET RUSTED OFF OF REAR END HOUSING, REAR SHOCKS RUSTED OFF. FRONT BRAKE ROTOR BACKING PLATES RUSTED THROUGH. THE VEHICLE IS UNSAFE TO DRIVE DUE TO FUEL LEAK AND EXTREME RUST THROUGH OF FRAME. I WANT THIS VEHICLE FRAME AND AXLE FIXED OR BOUGHT BACK BY TOYOTA. A TOYOTA DEALERSHIP IN AUBURN, ME KNEW OF THIS PROBLEM ALMOST 2 YEARS AGO AND SENT IT OUT THE DOOR. TOTALLY UNSATISFACTORY. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6). *TR

NHTSA ODI #10572597

Mileage unknown · Mar 13, 2014
Structure

MY VEHICLE IS A 2002 TOYOTA 4RUNNER SE5 WITH 112,080 MILES. I HAVE SEVERE FRAME RUST ON THIS VEHICLE. HOLES THOUGH FRAME ON RIGHT SIDE AND FRAME TO REAR AXLE IS COMPLETELY BROKEN TO RIGHT SIDE OF ATTACHMENT AT DIFFERENTIAL AXLE. TOYOTA HAS RECALLED THE U.S VERSION OF THE TACOMA TRUCK WHICH IS THE SAME FRAME, ETC. AS THE 4RUN…

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MY VEHICLE IS A 2002 TOYOTA 4RUNNER SE5 WITH 112,080 MILES. I HAVE SEVERE FRAME RUST ON THIS VEHICLE. HOLES THOUGH FRAME ON RIGHT SIDE AND FRAME TO REAR AXLE IS COMPLETELY BROKEN TO RIGHT SIDE OF ATTACHMENT AT DIFFERENTIAL AXLE. TOYOTA HAS RECALLED THE U.S VERSION OF THE TACOMA TRUCK WHICH IS THE SAME FRAME, ETC. AS THE 4RUNNER BUT NOT THE 4RUNNER WHICH IS MADE IN JAPAN WITH THE SAME ISSUES. THIS VEHICLE IS COMPLETELY UNSAFE AND TRUTH BE KNOWN UNDRIVEABLE AND NEEDS TO BE ADDRESSED IMMEDIATELY. TOYOTA 4RUNNER FORUM IS FULL OF THESE 3RD GENERATION 4RUNNERS WITH THE SAME ISSUE. TOYOTA NEEDS TO STEP UP AND ADD THE 3RD GENERATION 4 RUNNER TO BE INCLUDED IN THE RECALL ON THE TACOMA, TUNDRA AND SEQUOIA VEHICLES. *TR

NHTSA ODI #10569206

138,000 miles · Jan 9, 2014
Power TrainService BrakesStructure

VEHICLE FRAME, FRONT & REAR BUMPERS AND UNDERCARRIAGE HAVE EXCESSIVE / UNSAFE RUST CORROSION. *TR

NHTSA ODI #10559158

190,000 miles · Dec 19, 2013
Power Train

REAR AXLE ASSEMBLY ROT! NOW LEAKING ON REAR NON REPLACEABLE YOKE COVER. 1800-2000 DOLLAR FIX. TO MAKE THINGS WORSE AXLE ASSEMBLY HAS NO TAGS!!!! TOLD BY DEALER DOOR TAGS ARE OFTEN WRONG SO ORDERING RECYCLED (IF YOU CAN FIND ONE IN BETTER SHAPE) IS A GAMBLE!!!! HAS BEEN A DEPENDABLE TRUCK OTHER WISE BUT NOW IT SEEMS AS THOUGH…

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REAR AXLE ASSEMBLY ROT! NOW LEAKING ON REAR NON REPLACEABLE YOKE COVER. 1800-2000 DOLLAR FIX. TO MAKE THINGS WORSE AXLE ASSEMBLY HAS NO TAGS!!!! TOLD BY DEALER DOOR TAGS ARE OFTEN WRONG SO ORDERING RECYCLED (IF YOU CAN FIND ONE IN BETTER SHAPE) IS A GAMBLE!!!! HAS BEEN A DEPENDABLE TRUCK OTHER WISE BUT NOW IT SEEMS AS THOUGH THEY ARE PROFITING FROM THERE DESIGN FLAWS. *TR

NHTSA ODI #10556662

110,000 miles · Dec 3, 2013
Structure

TL* THE CONTACT OWNS A 2002 TOYOTA 4RUNNER. THE CONTACT STATED THAT THE FRAME AND UNDERCARRIAGE WAS SEVERELY CORRODED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS 110,000 AND THE CURRENT MILEAGE WAS 110,500.

NHTSA ODI #10554604

113,000 miles · Sep 30, 2013
Power TrainStructure

(THERE WAS NO CATEGORY OFFERED FOR FRAME). DURING A RECENT AUTOMOTIVE SERVICE FOR BRAKES ON 9-26-13 FOR MY 2002 TOYOTA 4RUNNER, I WAS NOTIFIED OF A RUST PERFORATION IN THE FRAME BODY NEAR A REAR SUPPORT MOUNT FOR THE AXLE MAKING IT UNSAFE FOR OPERATION. THIS IS A SITUATION WHERE RUST FORMS IN THE INTERIOR OF THE FRAME AND WO…

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(THERE WAS NO CATEGORY OFFERED FOR FRAME). DURING A RECENT AUTOMOTIVE SERVICE FOR BRAKES ON 9-26-13 FOR MY 2002 TOYOTA 4RUNNER, I WAS NOTIFIED OF A RUST PERFORATION IN THE FRAME BODY NEAR A REAR SUPPORT MOUNT FOR THE AXLE MAKING IT UNSAFE FOR OPERATION. THIS IS A SITUATION WHERE RUST FORMS IN THE INTERIOR OF THE FRAME AND WORKS ITS WAY OUT DESTROYING THE STRUCTURAL INTEGRITY OF THE VEHICLE. IT SEEMS THE SERVICE TECHNICIAN USED TO WORK AT A TOYOTA DEALERSHIP AND KNEW EXACTLY WHERE TO LOOK FROM HIS PRIOR EXPERIENCE WITH OTHER 4RUNNER FAILURES. THE TOYOTA DEALER INFORMED THAT THIS WOULD NOT BE COVERED. MY ?02 4RUNNER IS FROM THE SAME GENERATION (3RD) AND OF SIMILAR DESIGN TO THE TACOMA THAT WAS RECALLED FOR THIS THE DEALER INSTRUCTED ME TO CONTACT THE TORRANCE, CA TOYOTA CUSTOMER SERVICE AS HIS DEALERSHIP WOULD BE UNABLE TO ASSIST IN ANYWAY. IT WAS CLEAR THEY HAD ENCOUNTERED THIS BEFORE. THROUGH DISCUSSION WITH TOYOTA CA THEY HAVE NO INTENTION OF PROVIDING ANY MEANS OF RELIEF FOR A KNOWN AND WELL DOCUMENTED SAFETY PROBLEM. ONE REP DID COMMENT THAT THE TUNDRA AND SEQUOIA HAD BEEN RECENTLY ADDED TO THE RECALL BUT THE 4RUNNER WAS ?NOT YET? ON THE RECALL LIST. IT SEEMS TOYOTA VIEWS THE PRODUCTS TO BE DIFFERENT DUE TO THE BODY STYLE DIFFERENCES OR US VS JAPANESE BUILT PRODUCTS. THEY ALSO CLEARLY HAVE NO INTENTION TO ESCALATE INTERNALLY. I WAS INSTRUCTED TO FILE A COMPLAINT WITH NHTSA AND NTSB. RESEARCH ON LINE SHOWS THAT THERE IS A VERY WIDESPREAD ISSUE THAT TOYOTA IS CLEARLY CHOOSING TO IGNORE. WEB INFORMATION SUGGESTS THAT COLD CLIMATE AND THE AXLE BRACKET IN CLOSE PROXIMITY TO THE EXHAUST, ARE PRIMARY FACTORS. HOW CAN YOU RECALL ONE MODEL FOR A RUSTED FRAME DUE TO SAFETY BUT NOT ANOTHER? PERSONAL PHOTOS AVAILABLE. HUGE NUMBERS OF PHOTOS AND REPORTS AVAILABLE ONLINE - SEARCH " RUSTED FRAME 4RUNNER" OR SIMILAR. *TR

NHTSA ODI #10546324

Official recalls

1

05V225000 · Suspension:front:control Arm:lower Ball Joint

May 17, 2005

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