Frame/chassis problem- crack in fender well

[Jeremy556]

Small update on my cracks: I re-welded everything and installed a pelfry cage. Cracks moved again to new locations in short order.

I have now switched to an Odyssey group 34 on the passenger side.

I don't think huge hits are what cause it, but fast cyclic bumps, and I travel on a lot of very wash boarded roads. I suspect KDSS and 700 in lb front springs contribute to the harshness of the bumps as well.

 

[NoOneBetter]

Yay I have this crack too!
hwell:

Group 31M battery in a Pelfrey battery cage. I'm guessing its from hitting the top of the fender with 34's before I had better bumpstops. I was running the battery for a while with 32's and didn't have this issue.

 

[STX4Runner]

Bringing an old thread back to life...
I noticed today I have the same crack and I don't have an aftermarket bumper, heavy battery or winch, but I do wheel it fairly hard. So I just drilled the end and hopefully that'll stop it.

 

[Xtremluck]

You can add me to this esteemed crew. I have cracking on both sides. It’s more severe on the passenger side but a new crack has formed on the driver. Has stop drilling prevented further cracking for you all? I’m running stock sized batteries and a lighter front bumper/winch combo

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[BackOff]

Front body mounts toast?
Under the radiator area.

The get really chewed up on the 4th gen.

 

[Xtremluck]

Front body mounts toast?
Under the radiator area.

The get really chewed up on the 4th gen.

Ill definitely check those out this weekend.

It would seem that this problem is surprisingly common with folks who use their rigs offroad significantly. Out of the handful of 5th gen owners I know who wheel here in the Bay Area a good amount have this issue.

 

[BackOff]

Ill definitely check those out this weekend.

It would seem that this problem is surprisingly common with folks who use their rigs offroad significantly. Out of the handful of 5th gen owners I know who wheel here in the Bay Area a good amount have this issue.

Might be hard to tell just looking at them.
Noticed mine when i did the body lift... seems like blackworksinc keyed into this a while back.

 

[Xtremluck]

Might be hard to tell just looking at them.
Noticed mine when i did the body lift... seems like blackworksinc keyed into this a while back.

Were they worn to the point there was play? I've noticed a subtle chattering every time I start the engine and was originally thinking it may be an engine mount going but maybe it's this.

 

[Xtremluck]

They look pretty normal to me

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[BackOff]

I was just kinda thinking out loud.
You really cant see the front body mounts looking into the wheelwell.
Its internal to the mount.
i thought i took a pic but cant find it now.
Half the inside rubber was about gone.

Was just guessing too.
Maybe the bump stops are allowing the UCA to beat the upper fender to hell.
You guys have UCA dents in the top inner fender?

 

[007Tacoma]

about to get a 31M... Subscribing to remember where to go back to...

I have no cracks in my fenders, but I am subscribing here because I will be adding a 31M X2 Power Battery this weekend utilizing a LFD Battery Tray (full cage). Its been a huge debate of ours whether to go dual battery or go 27F or go 31M... 31M is winning because of budget, space, and time requirements

I fully expect to see fender cracks at some point.

So far, our 2015 4Runner Trail Premium has:

165,000 miles (maybe 10% hard off road)

Dobinson's Gas Struts
Dobinson's Springs for heavy loads providing 2" lift in front and 2.5" lift in the rear

That suspension carries the weight of:
LFD Hybrid Front Bumper with Engo SR10 Winch
LFD Front Skid
LFD Transmission Skid
LFD Transfer Case Skid
LFD Full length Roof Rack
SSO Rock Sliders
SnoMaster LP66D
Miscellaneous Recovery gear
LFD Dual Swing Rear Bumper
33" Kumho MT71s (C-Load)
Miniature Santa behind the wheel, one beautiful wife, and a future linebacker in the back seat.

When we run desert stuff, we tend to go pretty hard, but most of the stuff in Texas doesn't allow for high speed (cyclical vibrations) washboard roads like New Mexico, Colorado, Utah, and other open desert states.

 

[Vwright14]

I do have big heavy Odyssey battery as well...but stock bumpers, still uess I better check it.

 

[rdruss]

I read threads like this and I think "really, the FRAME is cracking?!" What does Toyota think is happening to 4Runners after they leave the lot? Many are not highway runners only like mine. This is totally unacceptable for the backbone of an off road vehicle, just like the rust problems on 1000's of frames!
I've said it before, but I think Toyota should have a "junior" engineer assigned to monitor this site and others like it so they know a little more about "the rest of the story" on their off road oriented products.

 

[Jeremy556]

I read threads like this and I think "really, the FRAME is cracking?!" What does Toyota think is happening to 4Runners after they leave the lot? Many are not highway runners only like mine. This is totally unacceptable for the backbone of an off road vehicle, just like the rust problems on 1000's of frames!
I've said it before, but I think Toyota should have a "junior" engineer assigned to monitor this site and others like it so they know a little more about "the rest of the story" on their off road oriented products.

It's the body, not frame. The overall number of units with these problems is very small, the majority (possibly all) of them are caused or greatly exacerbated by aftermarket modifications, and are not occuring during the warranty period.

 

[rdruss]

It's the body, not frame. The overall number of units with these problems is very small, the majority (possibly all) of them are caused or greatly exacerbated by aftermarket modifications, and are not occuring during the warranty period.

Thanks for the correction. I need to pay better attention to what's being discussed! I feel better about the Toyota frame already! Thanks.

 

[geofox784]

Has anyone figured out a lasting solution to this? I’ve got a heavy Genesis off-road dual battery kit and do a fair amount of hard wheeling. Just noticed the crack yesterday.

Had anyone welded some DIY fender stiffeners or attached additional bracing from the frame?

 

[Jeremy556]

Nope. Last welded mine on 1/3/21 and now need to do it again, after a trip down Hole in the Rock road a couple weeks ago.

 

[geofox784]

Nope. Last welded mine on 1/3/21 and now need to do it again, after a trip down Hole in the Rock road a couple weeks ago.

So the 1/8” bolt on plate you mentioned earlier failed? Do you think welding a 1/8” plate on would work? Did you ever make that strut?

 

[Jeremy556]

So the 1/8” bolt on plate you mentioned earlier failed? Do you think welding a 1/8” plate on would work? Did you ever make that strut?

Yep, still cracked with the plate. Welding on some material might work, or may just keep moving the failure down the line.

Never made the strut. Decided to get rid of the 31 and get the lightest deep cycle/starting battery I could find and moved it to the passenger side.

 

[ahtoxa11]

This was common on Gen1 Xterras, as well. Happens due to body flex when wheeling a lot. Battery may or may not exaggerate it, though, but likely it does.