gap between bumper and fender below headlight

[rblt]

Absolutely love my 2016 4Runner Limited, but have one irritation, being a noticable gap that exists between the bumper and fender below the headlight on the driver side.

I have had it in to the Toyota dealer twice now.
First time two months ago, they apparently put some felt in the clip/bracket assembly, and the gap was nice and tight like the passenger side until 20 minutes later after a very short drive, it had re-opened.
At that time they then ordered in a part which was back ordered and so just had the second shop visit today. Apparently, they did not replace the part that had been ordered, rather just did some adjustments to the existing alignment of bumper.
Again, it looked great when I picked it up, but again, after the 20 minute drive home on smooth pavement at less than 30mph ( rush hour ) the gap has re-appeared.

Picture shows the driver side gap on the left picture and the passenger side tight fit on the right picture.

Any others have a similar issue, and if so, what might be the fix?

 

[Bishop98]

Bring it back again and again until they fix it.

 

[noshareguy]

My buddy with a 2016 Limited also has this issue going on. Took back to the dealership and they don't know the reason as well. Must be a design flaw. Good Luck though - we'll be watching for a possible fix

 

[rblt]

Yes, I did already email a photo to the dealer. While I can wait until next scheduled maintenance in a couple of months to have another go at a repair, I wanted to let them know that the gap reappeared immediately so they don't suggest that I am bumping into things and causing it...

As I have not been off-roading or bumping into things, my initial guess was that the large and non-aerodynamic bumper was applying more pressure from wind resistance than the mounting brackets could sustain as we have done a lot of extended highway trips. While this may have caused the initial gap which did not appear for a few months, it seems that the slightest bit of driving will cause it to reappear.

Will continue with my patient persistence in getting this repaired under warranty...

 

[flea1983]

I have the same on the driver's side. There was another thread a while back about the same issue, definitely a Toyota issue and not an owner issue.

 

[nvbirdman]

Gee, I sure hope I don't have to declare this as a lemon over something that minor, but if you are unable to fix it after the many times I've brought it in I may have no choice.

 

[SWTrail]

Same thing in my 2016 Trail. Driver Gap is bigger. Maybe not as big as the picture though.

 

[T4RUNNER02]

I have a 2015 SR5 Premium and,unless, I am wrong the the body is exactly the same as 2016. Is it possible that the problem is resulting from one of the assembly plants in Japan? There are no gaps on my 4R.

 

[av8ter]

Bring it to the dealer's body shop instead of the service department, leave the vehicle with them, do not wait on the repair.

 

[reantone]

Any Resolutions

I have the same issue on the drivers side on my 2017 4Runner. Took it to the dealer body shop today. No resolution. I have considered super glue but am hesitant that it might make the bumper crack somehow.

 

[rblt]

I have the same issue on the drivers side on my 2017 4Runner. Took it to the dealer body shop today. No resolution.

Did the gap only appear recently after having owned the 4Runner for some time?

On a subsequent routine maintenance visit (24,000 km ), I did stop by the body shop desk just as one of the techs was coming back from his lunch break. The manager asked him what the common issue people have is and he answered with the bumper gap. He then came out to look at mine, laid on the ground and pulled forward hard on the lower edge of the bumper, to the point the vehicle was rocking in park. This would pull in the sides of the bumper, closing the gap. While it was not a documented service visit, it did actually resolve things for longer than the previous visits had.

I believe the underlying issue is that the factory installed the bumper cover brackets a few millimetres back from where they should be and thus the wind resistance during driving, pushes it back just enough to cause the side clips to loosen as they are designed to do in an impact situation.

I suspect that actually removing the bumper cover and re-installing it just slightly forward before tightening the bolts would apply the proper inward pressure on the side bumper clips to hold them tight and flush.

I haven't tried to convince the dealership to take the time to do a complete re-and-re of the bumper cover, but failing that, once warranty expires, I may just take it to an independent body shop with that request, or possibly try it myself following http://www.toyota-4runner.org/5th-g...ner-build-adventure-thread-8.html#post2335896 .

 

[supra8903]

me too -2018 limited

Just wanted to share that I am having the same issue. Based on my searching this is more than just one or two people.
I called Toyota and issued a case to hopefully drive attention to the issue.

Joe

http://www.toyota-4runner.org/5th-gen-t4rs/244110-gap-between-bumper-fender-below-headlight.html

http://www.toyota-4runner.org/5th-gen-t4rs/226590-2015-limited-bumber-faulty-clip-2.html

http://www.toyota-4runner.org/5th-gen-t4rs/220523-front-bumper-fender-separation.html

 

[oljedi11950]

If you guys goggle search front bumper removal you'll see it's all clips & plastic brackets , possible one broke or slipped off ! This would be how you replace headlights so pretty simple fix .

 

[Tisoy281]

If you guys goggle search front bumper removal you'll see it's all clips & plastic brackets , possible one broke or slipped off ! This would be how you replace headlights so pretty simple fix .

This is not the case. I have a 2014 Limited and have had the same issue since I bought the vehicle. They took it back 5 times to try and pop it back in place, only to pop back out when delivered back to me. The 6th time, they replaced the whole bumper. Here I am, 5 months later, and this bumper is doing the same damn thing. It's a design flaw. I opened a case with Toyota corporate, and they're aware of this.

 

[Engineer]

This is not the case. I have a 2014 Limited and have had the same issue since I bought the vehicle. They took it back 5 times to try and pop it back in place, only to pop back out when delivered back to me. The 6th time, they replaced the whole bumper. Here I am, 5 months later, and this bumper is doing the same damn thing. It's a design flaw. I opened a case with Toyota corporate, and they're aware of this.

Least it won't leave you stranded #notajeep

 

[Jemplyr77]

Known fault with the 4Runner. My limited did it on the passenger side. Called Toyota and opened a case with CS and took it to my local dealer. The rep agreed it is a known issue and kept it for a couple of days and took it to the certified Toyota body shop. That was months ago and no issues since...knocks on wood!:loco:

 

[BrianSJ]

Same issue here. 2017 Limited. I did have the LED Fog/DRL installed at port of entry. Not sure if all issues here are w/this option or not. The gaps are on both side (passenger and driver side). Can pop them in, but minutes later they pop back out.

I called Toyota, agent said "no known issue" when searching her records.

Bringing into dealer today to look at - curious to see what they will do.

 

[Gecko]

Same issue for me as well. 2016 Limited, 17k miles.

They replaced the clip on that side of the bumper and it is popping out once again.

 

[DeweyCheatemHowe]

I've got the same issue with my 2016 limited. Has anyone found a permanent fix? The dealership popped it back in last time and said if it keeps doing it the next step is a total bumper replacement. Has anyone had any luck with that? I would probably try to ask them to replace with a trail bumper to keep it from happening over and over but no idea if that would work, or if they'd be willing to accommodate the request AND install the parking sensors

 

[rblt]

Fixed

Waited a couple of months and 2,600km / 1,600 miles before posting this update to ensure it actually stayed in place.
Made a call to Toyota Canada in late January as my 3yr warranty will be up this coming July.
Appt set up with same dealership as previous visits. Apparently this time, rather than just pulling the lower edge of the bumper forward, they moved/bent a metal piece that the lower bumper rests against. I don't know the details but it has stayed in place so far, so I'm cautiously optimistic that it won't pop out again from road vibration/wind resistance.