2004 Toyota 4Runner Complaint Log

What component or system failed or malfunctioned, and is it available for inspection upon request? Response: Frame, Suspension, Airbags / Yes it is available for inspection. How was your safety or the safety of others put at risk? Response: Safety was put at risk due to frame & suspension failure due to severe rust. Also due to failure of deployment of AirBags. Rusted Frame Failure subsequently caused safety of Injured Party and other motorists to be at risk due to the Injured Party’s 4Runner to dart across oncoming lane of traffic with no warning other than a swaying motion felt immediately before losing control. Once the Injured Party lost control of the 4Runner it crossed into oncoming traffic, progressing into the drainage ditch on the oncoming traffic side of highway. Once the 4Runner impacted the drainage ditch at a 90° angle, the 4Runners momentum dispersed by causing the 4Runner to overturn 3 times landing on its wheels in the adjoining field. Has the problem been reproduced or confirmed by a dealer or independent service center? Repaonse: Independent Service Center has confirmed the problem with the Rusted Frame, Rusted Suspension, and Air Bag failure. Has the vehicle or component been inspected by the manufacturer, police, insurance representatives or others? Response : Yes Were there any warning lamps, messages or other symptoms of the problem prior to the failure, and when did they first appear? Repaint: No warning lamps prior to failure. Symptoms indicative of failure were an unknown minor swaying sensation while driving. Injured party was under the impression that there may have been a tire low on air, which was discovered to be incorrect later.

The body frame on this vehicle is almost completely rushed out. I don’t know what to do. If I should have the frame replaced I know there’s been a couple recalls on similar Toyota models.

The contact owns a 2004 Toyota 4-Runner. The contact stated that the frame was severely rusted. The vehicle was not diagnosed or repaired by an independent mechanic or a dealer. The manufacturer was notified of the failure and referred the contact to the NHTSA Hotline for assistance. The failure mileage was approximately 108,000.

Rusting frame, no specific incident date. Used today’s date.

2004 Toyota 4Runner SR5 - Frame rust: currently not drivable due to complete breakage from the rust. Driving 2 hours home on the highway I almost lost control, pressing/releasing the brake and/or gas pulls the steering side to side and sways the truck (fish tail) due to damage from the frame rust/breaking. There is no control of the rear end. Truck was in great condition prior to the frame snapping. Vehicle has been inspected by multiple mechanics (including Firestone, Welding/fabricating Auto Repair shops and small owned mechanic shops), possibly won’t be able to weld due to the amount of rust. Firestone won’t perform any service if the vehicle needs to go in the air (tires, oil..etc) due to frame rust. This has been a huge problem with Toyota, they addressed other models around the same year but excluded the 4Runner for unknown reasons. The dealership will not address the issue unless instructed by corporate. This problem jeopardized my safety and the safety of others around while I was driving at highway speeds, there was no warning when it occurred. Vehicle is available for inspection any time, as it currently is not going anywhere without a tow.

Excessive frame and suspension corrosion that could lead to serious accidents if not repaired at a very high cost for myself

Frame rust. Huge problems on the 4th gen 4runners. Can't believe there's not a recall on this issue.

Extensive frame rust to the point of structural failure. Cannot support weight or force.

Undercarriage frame rusted to the point where structural rust was formed in various places This rust has made a whole and cracks to the frame causing my vehicle to become a safety hazard on the road

I recently bought a 2004 Toyota 4 Runner and the frame of the vehicle has significant corrosion to the extent of holes, weld failures and more. I've never seen frame rust so bad on a vehicle like this. I'm a little uneasy about the safety of this situation. I think Toyota should replace the frame or give a good discount on the part and labor. I hope someone can help me out with this concern.

Cars frame is rotting out to the point it is not safe to drive. I was told being in a collision could cause catastrophic failure and the car is just turning 20 years old with 125,000 miles. Can’t get my money back and the car is otherwise is excellent condition.

Frame is severely rusted and has holes started at 40k miles

Something is causing the straps to fray I was informed this is a a problem, checked my seat and sure enough my straps are fraying. Evenflo says it’s my fault.

Took 2004 Toyota 4Runner SR5 to Toyota dealership to be serviced. Dealership called me to explain unable to do alignment, due to rear back frame excessive rusted through. Dealership advised waste of money to align new tires just purchased, unable to even do alignment and it was dangerous. Now what is to be done? This is my daily driver for work. How did this happen that its unsafe and dangerous to drive.

UNKNOWN: Excessive frame rust. frame is excessively rusting to the point where the brakes and suspensions is connected to the frame has been compromised. brake lines rusted to the point of failure, thus almost causing a wreck. Vehicle is now parked due to safety concerns involving the excessive rusting that is happening to the frame and any components that is attached to the frame.

2004 4Runner rear hatch glass imploded with rear defroster on while driving and glass shattered all inside the vehicle in the back behind rear passenger seat. The loud sound when it imploded sounded like we had got shot at and scared all four of us in the vehicle thinking we were shot at. We pulled the vehicle over at the nearest pull over while driving on a coastal two lane road. We searched for any possible bullets. Did not find any and had to clean up as much possible of shattered glass that had covered all of our clothing and belongings. Had no materials to cover the rear broken window and had to continue our drive to meet family members to attend an early event at 9:00 am.

The rear tailgate window shattered while vehicle was in driveway as soon as it was turned off. Before it shattered there was an odor of something like plastic burning. Fortunately no one was hurt by the exploding bits of glass. The sound the breaking glass make was loud and startled the passengers. Good thing the vehicle was not in motion on the street or highway. On the internet I saw where other people shared the same problem on their Toyota 4Runner. Then I saw that Toyota had put out, TSB-0189-17, which stated exactly what happened to my 4Runner. Due to this possibly dangerous incident this should be upgraded to a vehicle safety recall.

Excessive frame rusting. There are holes in the frame from rusting. At this point in time there isn’t anything I can do about the issues. Frame is unrepairable.

Unknown: we were on [XXX] when the car went out of control. It first spun one way and then the other way and then we hit the concrete abutment where the guardrail connects to it. We hit it head on. It was as if we were on ice or oil, unable to gain control or brake. We checked the road and it was dry. Other cars were going by with no problem. The airbags didn’t deploy. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

I own a 2004 Toyota 4runner Sport Edition that suffers from frame rust issues. Mine isn't as bad as I've seen in person while working at a Toyota dealership as a tech or on the forums but from my experience in assisting in replacing frames at the dealership I know that my frame won't last very long. When I bought it from the original owner it had around 86,XXX miles on it and the typical spot in the from was rusted out. I choose to purchase it because it was the best example I could find, others having worse rust. I quickly discovered a weak spot which became a hole when trying to jack it up to do work along with chunks of rust that came off the rear end of the frame and all over. The weak spot that ended up being a hole seems to be caused by the AC drain location and how it drips right onto the frame which has an opening right by where it drips. I believe the drips went into the frame through the factory hole and lead to the weak spot and hole in my frame. I am not the only one who has experienced this issue. In fact on a Toyota 4runner forum there is threads on people extending the drain to prevent the same thing from happening to theirs or from getting worse. As a former Toyota tech who has seen how bad the frames that came in under recall and 4runner frames were first hand I cant believe that a the 4runner frames weren't included in the recalls. I've seen countless threads/reviews/complaints of severe rust causing accidents from suspension components. Toyota should be held accountable for the rust issues ont he 4runners just like the other vehicles. My 4runner now has 113,xxx on it and it will rust out long before the drivetrain gives out no matter what I try to do. My only option is to fix it using safe t caps when the time comes who makes frame fixes for Tacomas, Tundras, FJ crusier and of course the 4runner. They produce them for these vehicles because the frames rust out pre maturely. The rusty 4runner frames are a safety issue and should be addressed.

Rusted frame

The contact owns a 2004 Toyota 4Runner. The contact stated while driving 55 MPH, the ABS and the brake warning lights illuminated. Additionally, there was an abnormal humming sound coming from the dash. The contact stated while approaching another vehicle, he depressed the brake pedal, but the vehicle failed to respond, nearly causing a crash into another vehicle. The contact immediately shifted into neutral(N) and veered to the side of the road while continuously depressing the brake pedal, and the vehicle stopped. The contact was able to continue driving. The vehicle was taken to an independent mechanic, where it was diagnosed that the ABS pump had failed. The vehicle was not repaired. The dealer was notified of the failure. The vehicle was not repaired. The manufacturer was not notified of the failure. The failure mileage was approximately 350,325.

Frame of this vehicle completely rusted through. Holes on passenger side right where the front door ends. Hole is approx 12" long. Frame also has a hole in the left front core support. Advised that the vehicle is no longer safe to drive by my Toyota Dealer and personal mechanic. . There were no indications of this until a few weeks ago when the gas tank strap had come off and the gas tank was leaning. When inspected, it was found the frame was in disrepair.

Entire frame of the vehicle is rotten with rust and holes. This vehicle has been inspected by McDaniel Toyota, Marion, OH 43302 and the damage was confirmed. I have been and must continue to drive this vehicle even though the dealership did not recommend it. No evidence of the extent of the rust and damage was not noticed until October 2023 when a strap on the gas tank came loose. Upon further inspection, he noticed the holes and rust all over the frame. Reported to Toyota because other 2004 Models were recalled for this issue. They were of no assistance.

The contact owns a 2004 Toyota 4Runner. The contact stated that while the vehicle was in for service, the independent mechanic discovered rust on the front driver's side subframe. Additionally, the subframe had developed holes due to rust. The cause of the failures was not yet determined, and the vehicle was not yet repaired. The manufacturer and local dealer were notified of the failure, but no assistance was offered. The failure mileage was 120,000.

The frame of the vehicle rust just as same as the 03-09 Tacoma and there is nothing I can do the fix it and if I get new parts it ruins my Parts after a short period of time

The frame of my Toyota 4-Runner has developed holes making it dangerous to drive.

The contact's mother owns a 2004 Toyota 4-Runner. The contact stated that after the vehicle was taken to an independent mechanic for a routine oil change, his mother was made aware that the subframe had excessive corrosion, and that the subframe needed to be replaced. The mechanic informed the contact's mother that the vehicle was not safe to drive. The vehicle was not repaired. The manufacturer was not made aware of the failure. The failure mileage was 180,330.

Frame rusted through on left rear of vehicle were suspension parts are attached.

The contact owns a 2004 Toyota 4Runner. The contact stated that while the vehicle was in for routine service, it was discovered that the subframe had sustained severe rusting and corrosion. The contact indicate that there was a hole going through the subframe while the vehicle was being lifted at the service center. The local dealer and manufacturer were notified of the failure and informed the contact that the VIN was no longer covered under the Manufacturer’s Extended Warranty coverage for the failure. The approximate failure mileage was 146,000.

Frame is falling apart rusted right out unsafe to drive a truck I'm making payments on.

Frame and body prematurely and aggressively rusted despite constant care and upkeep. Toyota recalled the exact frame on their Tacoma of the same years and did not recall the 4runner frames. It’s criminal and dangerous to the user and other vehicles on the road.

-The frame is rotted out - If the frame were to break, which my mechanic i saying is very possible, a massive incident could occur - It has been confirmed by an independent service center - It has not been inspected by the manufacturer but is an astonishingly common issue Toyota is very aware of that they continue to ignore. - There were not indicators notifying me of the issue. I wanted to replace my suspension and the mechanic advised not doing so because of the rot.

The frame is damaged from excessive corrosion. The rear cross member that supports the trailer hitch and rear bumper is almost non-existent, which could result in the loss of the trailer being towed, and it will reduce the truck's rear impact resistance. The front right lower control arm has a 2'" x 3/8" lateral hole from corrosion, which could result in a catastrophic failure of the right front suspension system. The longitudinal frame members are compromised by corrosion which has penetrated through the steel in various locations. The front cross-frame member that supports the radiator is severely corroded. The frame to body mounts are showing signs of excessive corrosion which could result in the separation of the the body from the frame in an accident.

The undercarriage is full of rust that the repair shop will not test drive or fix due to the issue. No warnings.

The frame is showing significant rust damage throughout the frame. A hole was punctured in the passenger side while using the factory bottle jack. This could have ended badly if someone was underneath when this happened. Furthermore there is deterioration on the front and rear sections that are questionable as to their integrity and resilience in the event of a crash. It is generally accepted by other owners of this generation that lack of adequete drainage throughout the frame has led to water pooling inside and creating excessive rust issues from the inside out.

The truck frame is rusting and making the vehicle unsafe prematurely. My vehicle only has 78 thousand miles and likely needs the frame replaced like many other toyota vehicle because of the lack of corrosion protection.

We took our 2004 4Runner for annual vehicle inspection and the service provider told us the vehicle would not pass safety inspection due to the excessive rusting on the steel frame and the suspension of the vehicle. Welding and patchwork will not fix this issue. My husband depends on this vehicle to work. The attached pictures give a small window into the extent of the damage. There is no current recall for this vehicle and year, but similar Toyota trucks from the same time frame have been recalled for the same exact issue. The entire frame needs to be replaced or worst case scenario, the vehicle is no longer usable. Toyota needs to remedy this issue for their loyal customers immediately.

The body frame is the problem, it has rust all around, the radiator supports are all rusted out almost hanging, front side of the frame and rear side are clearly rusted. Radiator could fall any time. The problem was confirmed by auto shop and inspection shop (independent service center). Vehicle has not been inspected by police or insurance representatives. There were no warning lights or symptoms prior to frame failure, for now.

The frame of my 2004 Toyota 4Runner, which is manufactured by Dana Holding Corporation, is the primary support structure of my vehicle, to which every piece is attached. It is the main protection against injury in a car accident. The excessive rust corrosion of the frame on my Toyota 4Runner greatly hinders the safety, crash-worthiness, and stability of my automobile, as transmission mounts, essential suspension components, and engine mounts are attached to it. Consequently, as it becomes affected by rust, it is significantly more prone to failing to protect me, the driver, in a car accident, and, furthermore, it can also cause serious accidents in and of itself. Depending on the gravity of the impact, not only myself but my passengers (my young children) can experience a wide range of injuries and even death. Because the excessive rusting of the undercarriage of my Toyota 4Runners can cause plenty of vehicle components to fail, there can be multiple causes for an accident. The following are the most common injuries people sustain after a car accident: traumatic brain injuries severe whiplash fractured bones lacerations spinal cord damages paralysis loss of limbs permanent scarring concussions internal bleeding head injuries face injuries compound fractures soft tissue damage back injuries dislocated bones knee injuries shoulder injuries herniated disc psychological injuries Unlike in the case of other models of your vehicles, Toyota Motor Corporation refused to address the problem of 4Runners. Interestingly, your company faced a previous lawsuit in 2016 concerning the same rusting problem in the Tacomas, Sequoias, and Tundras, and it was settled for $3.4 billion in 2020. Nonetheless, your company did not admit it manufactured defective vehicles. According to documentation, Toyota Motor Corporation had been aware of the issue of premature rusting of the undercarriage of their 4Runners for a long time but continued to manufacture and sell defective vehicles.

The body is excessively rusted through. Other vehicles this age or older do not have any where near the amount of excessive rust and holes. Parts have fallen off. Anytime the shop has to work on the truck, there is a pile of rust under it. Broken off rust poses a hazard to owner and others on the road as debris. Known issue on an uncoated frame.

Extreme Rusting on the frame undercarriage of the vehicle. Our mechanic found it today - said it must have been rusting for years & that this is a common problem with 03 - 05 Toyota 4Runners.

Unaware of frame rusting issues to vehicle.. Observed rust through carpet on driver side. Upon research safety is a concern. Due to high volume of this type of issuing occurring a safety recall should be issued. It was not verbalized at time of purchase the make and model of vehicle have these type of issues. Especially, when this issues had been occurring prior to purchase of this vehicle.

The chassis is completely rusted/rotten, 1" Holes throughout the chassis and was told that it won't pass inspection.

I bought my 2004 Toyota 4runner Sport edition as a new car, and have been the sole owner of the vehicle. I have taken good care of it the entire time. Regular car washes, service maintenance and necessary repairs over time. I recently had my 4runner in for repairs and spent a considerable amount of money, over $6,000 in anticipation of driving it for many more years. Following the repairs I was told by the mechanic that the frame was EXTREMELY rusted and that the entire frame would need to be replaced. There are large holes rusted through in many areas of the frame and a tremendous amount of rust over the entire frame. Rusted Pieces of the frame have fallen off. I fear for the safety of my family and me if I were to drive the vehicle at all. I have barely driven it since learning of the dangerous condition of the frame. I've limited any driving at all to my immediate area, and have driven very carefully and slowly, as I am extremely concerned that there might be a catastrophic failure of the frame while driving and I may be injured or killed, or worse....the vehicle might cause harm or death to another person. I am now basically without a vehicle and have been forced to rely on my daughter's car, leaving the family with only one vehicle. This is a major failure of the vehicle. I can provide photos and video at your request. Toyota must be held accountable for the failure of this frame. The vehicle is now useless. I expect Toyota to rectify this situation immediately. Please contact me as soon as possible. Thank you. [XXX] INFORMATION Redacted PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6).

The frame is rusted through on this 4Runner. Same frame as the tacomas that were recalled and I’m wondering why Toyota wouldn’t recall THE SAME EXACT FRAME WITH MAJOR RUST ISSUES on a different platform. This truck is not abused so it’s very frustrating to see it falling apart at the frame when everything else is intact and solid. The rot on this frame is inevitable. I’m going to be very upset if I have to pay out of my own pocket for something that should be 100% covered under recall. This is a huge safety hazard and could lead to serious injury or death.

2004 Toyota 4 runner frame is corroded so bad and dealer mechanic thinks it is a default of manufacturer and suggested I file a complaint with you. He said many Toyota 4 runners having same issue and it is a safety hazzard.

The right rear control arm mount completely rusted away from the frame. Causing it to start fish-tailing out of control. Also there are other mounts that have rusted through. Like for instance, the gas tank strap mounted to the frame. There are also more areas of the frame that are rusting through. I'm just glad that I was the only one in the vehicle and going slow enough to not cause an accident. I then took it to an auto repair shop and they informed me that the frame on my vehicle has many problem areas of being rusted through. I have attached some photos of the problem areas taken from the repair shop.

Underbody of vehicle is rusting away from vehicle body, I was made aware of situation at a service appointment in April of 2022, no vehicle collision or wreck has happened because of it yet,

My Car was inspected by a Virginia Inspection Station and was cited for significant rust holes in the frame which have to be repaired. The frame should not have such significant rust that it needs to be fixed or it will be a hazard on the road. Based on other litigation around Toyota fames from this period of time is seems that this is a systemic issue and should be made to provide a recall based on the safety risk that is present with a frame failure as noted in previous class-action lawsuits. The Brian Warner et al. v. Toyota Motor Sales, U.S.A., Inc., Class Action Settlement (UNITED STATES DISTRICT COURT FOR THE CENTRAL DISTRICT OF CALIFORNIA Case No. 2:15-cv-02171-FMO-FFM) is a perfect example of the risk to the public if this is not corrected.