Feds look at frame rust

[Richmond Dan]

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.

 

[jhguth]

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.

 

[Sparman]

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

 

[Cadesun]

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.

 

[CoolMax]

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.

 

[Salvo Jimmy]

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.

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.

 

[frankramo777]

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

 

[drapaki]

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.

 

[jhguth]

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

 

[Inv4drZm]

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

:rofl:

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.

 

[thecalm_7]

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.

 

[EddieV4runnin]

Move to another state

 

[Orc]

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.

 

[Frederick1]

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.

Back in the olden days when I was a kid most cars were trash about the same time they were paid off. Shortly after three years you could figure on replacing many parts.

 

[GreenPM]

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.

I have the same on my 2015. Same spot. Not enough reason for me to want to sell it though.

 

[thecalm_7]

I have the same on my 2015. Same spot. Not enough reason for me to want to sell it though.

80000 miles, 3 new AC Blower fans (400 parts and labor), 3 Driver Door Actuators (800$ parts and labor each), soon to be 3 on passenger side, issue with passenger seat chiming like someone isn't wearing belt (dealer wants over 1000$), navigation/Bluetooth/headunit never worked correctly (2500), new window motor in 3 windows (400 each). Driver side front sounds like im torturing a cat when using it, neither rear charger work. replaced wiper motor too. Various weather stripping has gotten sticky/tacky, cracked, rear 4 runner plaque cracked (300)
I bought the 4runner to be able to go through some areas where ground clearance is an issue, nothing special, no luxury features, just a purpose built truck. However at 5000miles, I did have these issues, and the dealer ignored them with BS excuses of no CEL=No fix, so all of this is on my dime. I have nexer had to replace so many parts or have so many gremlins constantly in a vehicle with so few features. I am in FL so AC is a must, Locking my doors is a must. Frame rust I don't care about really, but it is a shame considering I still have an S10 with 400k with less rust and have only had to replace the 3rd door handle and radiator) Aside from taking it to the dealer to find out whats wrong, Im replacing the parts with OEM. My MINI while running inconsistent didn't give me this kind of problem. If it were lux features, sure, but necessary funtions of the vehicle shouldn't have this kind of failure. I baby this thing compared to many on here. I like RWD and ground clearance and wanted internal storage vs a conventional truck bed.
Im happy for everyone who has a reliable runner, but mine is not. Being paid off and 80k on the ODO, its time to say get rid of it before something else comes along.

 

[GreenPM]

80000 miles, 3 new AC Blower fans (400 parts and labor), 3 Driver Door Actuators (800$ parts and labor each), soon to be 3 on passenger side, issue with passenger seat chiming like someone isn't wearing belt (dealer wants over 1000$), navigation/Bluetooth/headunit never worked correctly (2500), new window motor in 3 windows (400 each). Driver side front sounds like im torturing a cat when using it, neither rear charger work. replaced wiper motor too. Various weather stripping has gotten sticky/tacky, cracked, rear 4 runner plaque cracked (300)
I bought the 4runner to be able to go through some areas where ground clearance is an issue, nothing special, no luxury features, just a purpose built truck. However at 5000miles, I did have these issues, and the dealer ignored them with BS excuses of no CEL=No fix, so all of this is on my dime. I have nexer had to replace so many parts or have so many gremlins constantly in a vehicle with so few features. I am in FL so AC is a must, Locking my doors is a must. Frame rust I don't care about really, but it is a shame considering I still have an S10 with 400k with less rust and have only had to replace the 3rd door handle and radiator) Aside from taking it to the dealer to find out whats wrong, Im replacing the parts with OEM. My MINI while running inconsistent didn't give me this kind of problem. If it were lux features, sure, but necessary funtions of the vehicle shouldn't have this kind of failure. I baby this thing compared to many on here. I like RWD and ground clearance and wanted internal storage vs a conventional truck bed.
Im happy for everyone who has a reliable runner, but mine is not. Being paid off and 80k on the ODO, its time to say get rid of it before something else comes along.

You sound like the most unlucky 4runner owner I've ever heard of. I'm at 80k miles and don't have any of those problems, except for the Bluetooth. That can be glitchy, but I don't use it much so I don't notice.

 

[catrains]

if in Miami your driving in salt water when a strong east wind blows.

I was a few miles north of Miami and there was a 40MPH easterly wind blowing my vehicle was totally covered with sea salt as those waves 500ft away created the salt spray to travel a very long distance ..

I live in rust belt but not on the sea coast .. 25miles inland .