August 21, 2018 — Toyota 4Runner frame rust problems will be looked at by the National Highway Traffic Safety Administration (NHTSA) after a 4Runner owner complained the steering and suspension system separated due to corrosion of the frame.

NHTSA says it will either grant or deny the petition to investigate once it checks complaints and field reports about rusted frames in more than 520,000 model year 2002-2006 Toyota 4Runners.

The petitioner alleges he was on a two-lane highway in his 2005 4Runner when he had trouble controlling the SUV after the suspension failed without warning.

According to the petition to investigate, 4Runner owners claim the frames experience excessive corrosion and the same type of frames were cited in a previous $3.4 billion class-action lawsuit.

Included in the lawsuit were about 1.5 million Tacoma, Tundra and Sequoia trucks, but the petitioner says the 4Runner should have been included but the attorneys didn't think there were enough customer complaints.

NHTSA says it couldn't identify any crashes or injuries related to rusted frames or suspensions, but owners have complained about almost losing control of the SUVs due to rusted axles and frames.

"Frame rusted out and rear axle support detached from frame while driving, causing vehicle to sway uncontrollably almost rolling over. Found that manufacturer has recall on trucks with similar frame for rust issue, but not this vehicle because there are not enough complaints or deaths." - 1998 Toyota 4Runner owner / Burlington, Kentucky

Once safety regulators check the data, it's possible they could open an official investigation to determine if the 4Runners should be recalled.

CarComplaints.com will update our website with NHTSA's decision to either grant or deny the petition to investigate frame rust in Toyota 4Runners.

are there complaints on the 5th gen? this seems limited to the 4runners that were contemporaneous with the other models that had their frames replaced.

The affected years range seems odd, with 2002 being the last year of the 3rd gen.

Ou 2005 had brutal frame rust on the front end. My mechanic looked into it several times for recall because he had seen it a lot on that generation but nothing. Buyer beware if looking to pick one up of this vintage.

2002-2006...so not a 5th gen.


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4th gen is notorious for horrible radiator support frame beam rust because that area is completely unprotected. 5th gen took care of that by adding plastic cover that bridges front bumper and skid plate.

My 2004 had similar problems at about the 10 yr point, but Toyota would do nothing. Reason given not enough complaints at that time. It was logged by them.

Couple yrs later while trying to tow it (transfer case failure) the front tow hook failed, rusted. Replaced it with current 2016.

take your 4runner in for a frame inspection at the local dealer, then submit the findings to the national highway traffic safety administration.

https://www-odi.nhtsa.dot.gov/VehicleCom

Also contact the law firm that sued Toyota to fix the rotten frames. we all know that the 4Runner rots the same way the Tacoma, Tundra and Sequoia trucks are rotting.. Why the hell should we be left swinging in the wind and having to junk our trucks??

https://bholaw.com/contact.html

I contacted the law firm and subscribed to this thread. I would ask that any news on the matter be reported here.

I missed out on the dash replacement and kick myself every time I see those cracks.

i'd suggest you make a thread in the 4th gen section, as this doesn't impact any 5th gens it's unlikely to have a lot of information posted here

Believe me we have more than enough threads on this topic in our section



If you look at the pictures this petitioner supplies literally everything has a coat of rust. Skid plates, shocks, control arms, suspension links, differentials... no way he can rightfully blame Toyota for not manufacturing the frame correctly, the entire vehicle was abused, practically was parked in the ocean from the looks of it.

Not true! My 2004 gets wash after each snow storm or any time roads are treated in the winter and my radiator support is nearly rusted trough in many spots. That cross member also has two recovery hoops which I wouldn't use at this stage of rust damage.

Im soon to sell my 2015 4Runner as it is the absolute worst vehicle I have had in terms of reliability. I noticed upon my last wash, that the frame has rust and the brackets supporting my radiator and heater are rusting.
That being said, I never drive in snow, I never drive in salt or brackish water. I admit to driving through water nearly up to my doors as we have had flooding on some of the low roads and my wife can not make it to work in her Lexus.
Other points of rust are the bolt on the front of the motor holding pulleys and several other spots. Rear suspension has some rust as well.

Move to another state

Japanese cars always did rust bad. VW was the first brand to galvanize both sides of the sheet metal on all panels even the roof. Keeping vehicles 10 years and expecting anything other than a old vehicle that's due to be replaced is crazy.