Has the rusted frame problem been corrected

8borerifle

Junior Member
Did Toyota solve the frame rust problem with the 25 4Runners?I owned a 2009 4Runner and a 2011 4Runner and BOTH frames rusted out. 2011 had 87000 miles and heated garage kept and the 2009 had 90000 miles and also heated garage kept. I live in Ohio.I loved both 4Runners and am looking for a 2025,just don't want to get stuck with another rusted frame!
 
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Seems you are wanting to know about factory frame coatings inside & out.
Probably too soon for evidence to show up.
Pure iron is very rust proof. However, alloy steel is easily rusted. The coatings are the only protection. New auto high strength alloy steels are purposely thin for weight savings-but can be ruined by rust.
The owner can assist by keeping salt brine off the steel undercarriage with cleaning after exposure. Same goes for moisture trapping dirt & mud.
The manufacturer can design with components that do not trap and hold these contaminants.
Lets hope Toyota is striving to improve its historic frame rust issues.
 
The only Toyota frames with corrosion issues due to poor manufacturing, were those produced by Dana Corp for Toyota. Toyota replaced a lot of frames, or bought vehicles back. They also won a large lawsuit against Dana Corp.

The 4Runner never had a frame made by Dana Corp, as 4Runners have always been made in Japan. So it was not part of that frame replacement/ buyback campaign.

Now anything can rust or corrode in a highly corrosive environment, if sufficiently neglected.

Every owners manual I've ever owned specified cleaning off Salt etc. regularly, when used in a highly corrosive environment.

If you had rust issues, it's because you neglected to clean it often enough.

Having worked on all makes and models where neglected vehicles eventually rust/corrode away, I can say that all brands are susceptible to owner neglect.

I doubt Toyota has done anything different to protect further from rust. So I'd suggest that whatever you buy, be more proactive in keeping the rust at bay.

Incidentally, I owned a 3rd gen 4Runner for 22+ years from new. It was operated on Salt encrusted roads all winter long, and on the Bonneville Salt Flats every year for Speedweek.

When I sold it it had no rust, as I washed it frequently (particularly the undercarriage) whenever it had been operated in that highly corrosive environment. So that could have been several times per week during winter.

People that live in the rust belt either take steps to keep rust at bay, or the cost of having to replace a vehicle sooner than later, becomes the cost of living where we do, and/or the choices we make.
 
Did Toyota solve the frame rust problem with the 25 4Runners?I owned a 2009 4Runner and a 2011 4Runner and BOTH frames rusted out. 2011 had 87000 miles and heated garage kept and the 2009 had 90000 miles and also heated garage kept. I live in Ohio.I loved both 4Runners and am looking for a 2025,just don't want to get stuck with another rusted frame!

Sounds like parking trucks with fully boxed frames inside heated garages after saltwater baths is the surefire way to rot them out.
 
The only Toyota frames with corrosion issues due to poor manufacturing, were those produced by Dana Corp for Toyota. Toyota replaced a lot of frames, or bought vehicles back. They also won a large lawsuit against Dana Corp.

The 4Runner never had a frame made by Dana Corp, as 4Runners have always been made in Japan. So it was not part of that frame replacement/ buyback campaign.

Now anything can rust or corrode in a highly corrosive environment, if sufficiently neglected.

Every owners manual I've ever owned specified cleaning off Salt etc. regularly, when used in a highly corrosive environment.

If you had rust issues, it's because you neglected to clean it often enough.

Having worked on all makes and models where neglected vehicles eventually rust/corrode away, I can say that all brands are susceptible to owner neglect.

I doubt Toyota has done anything different to protect further from rust. So I'd suggest that whatever you buy, be more proactive in keeping the rust at bay.

Incidentally, I owned a 3rd gen 4Runner for 22+ years from new. It was operated on Salt encrusted roads all winter long, and on the Bonneville Salt Flats every year for Speedweek.

When I sold it it had no rust, as I washed it frequently (particularly the undercarriage) whenever it had been operated in that highly corrosive environment. So that could have been several times per week during winter.

People that live in the rust belt either take steps to keep rust at bay, or the cost of having to replace a vehicle sooner than later, becomes the cost of living where we do, and/or the choices we make.

Good luck getting disgruntled rotted 4Runner frame owners to understand a manufacturing issue vs a design/specification downside.

Remember this crybaby's fiasco? Thrown out for negligent misrepresentation in 2023. This is no frame issue with any gen 4Runner as it relates to how it was designed or manufactured. Even the NHTSA denied his petition. No one has yet to build a solid case.
 
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Good luck getting disgruntled rotted 4Runner frame owners to understand a manufacturing issue vs a design/specification downside.

Remember this crybaby's fiasco? Thrown out for negligent misrepresentation in 2023. This is no frame issue with any gen 4Runner as it relates to how it was designed or manufactured. Even the NHTSA denied his petition. No one has yet to build a solid case.

Yeah, that thread and more of people complaining about their neglected 4Runner rusting when operated in a highly corrosive environment...

For the record, my 5th gen is now over five years old, and it's operated in the same conditions as my old 3rd gen was.

ZERO RUST. :thumb:

Look at this pristine frame that has had the Salt washed off when necessary.
 

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Yeah, that thread and more of people complaining about their neglected 4Runner rusting when operated in a highly corrosive environment...

For the record, my 5th gen is now over five years old, and it's operated in the same conditions as my old 3rd gen was.

ZERO RUST. :thumb:

Look at this pristine frame that has had the Salt washed off when necessary.

Youtube suggested me this today.

<iframe width="560" height="315" src="https://www.youtube.com/embed/WhK7jkQUhBQ?si=7bjBqgSXRfOxWJ02" title="YouTube video player" frameborder="0" allow="accelerometer; autoplay; clipboard-write; encrypted-media; gyroscope; picture-in-picture; web-share" referrerpolicy="strict-origin-when-cross-origin" allowfullscreen></iframe>

Should Ford fix that clear "design flaw" and replace all frames with an upgraded C channel design?
 
A heated garage isn't going to help with rust if you don't wash the salt off before putting the vehicle in the heated garage.
 
I don't believe 4Runners are significantly more prone to rust than other box-frame vehicles. They just last longer and retain their value better so people keep them on the road until they rust out.

Use fluid film or similar and be vigilant about rinsing out the frame if/when any salt builds up in the little drain holes and you'll be just fine.
 
Short answer: not really — frame rust/drainage problems are still a concern, and it doesn’t appear Toyota has “solved” them fully (as of publicly available info). But the risks and severity may differ between the 2017 (5th-gen) and 2025 (6th-gen) models. Here’s a breakdown of what I found, and what to watch out for.

What’s the “frame rust / drainage / water pooling” issue?

Many owners note that fully boxed frame sections (closed C-box style, or double rails) can trap moisture or road salt inside if there is no proper drainage or if sealing fails. Over time, internal corrosion (from the inside out) can occur.

In older 4Runners (especially 2000s era), there are documented cases of premature frame corrosion — e.g. a class-action suit for 2003–2009 models.
The Nicks Law Firm
+2
Top Class Actions
+2

Even in modern 5th-gen (2010–2023) 4Runners, owners frequently talk about underbody rust, bubbling paint, and frame/floorboard corrosion in high-salt or coastal regions.
Toyota 4Runner Forum
+3
Toyota 4Runner Forum
+3
Toyota 4Runner Forum [4Runners.com]
+3

Some of the specifics you mentioned (pooling, needing to drill drain holes) have been brought up in forums—people sometimes drill or open holes, or force drainage in boxed rails, or apply rust inhibitors.
 
Did Toyota solve the frame rust problem with the 25 4Runners?I owned a 2009 4Runner and a 2011 4Runner and BOTH frames rusted out. 2011 had 87000 miles and heated garage kept and the 2009 had 90000 miles and also heated garage kept. I live in Ohio.I loved both 4Runners and am looking for a 2025,just don't want to get stuck with another rusted frame!

This isn't intended to pile on or pin blame on you, but serious question: Did you ever wash the belly of the car in the winter? Like run it though the auto drive-through wash with undercarriage rinse, or get down there yourself? I ask because I see that there are people that do that seemingly everytime their car touches salted roads, and others that just let it ride in the same conditions. Coming from down south, washing the underside of the car was not a thing. Ever. But up here in NE, you either spend the time to do the underbody maintenance (or pay someone to do it) or you sell or trade in the car every few years and don't deal with it at all. Anyhow, I don't know where I'm going with this other than I sympathize as I'm in the same situation even after spending many many hours cleaning and spraying my 2008 and now I'm at that decision time. At least tell me you were able to get some money for the crust buckets? :D
 
Anyone have any experience, thoughts on effectiveness of an oil-based undercoating in the rust belt?

Look up a channel on Youtube called RepairGeek. He has long term results on lanolin based undercoatings on new and already rusted vehicles. I spray any metal part or cavity with the stuff. It works very well.
 
Anyone have any experience, thoughts on effectiveness of an oil-based undercoating in the rust belt?

one of the pro mechanics (who happens to have a YT channel) said that oil-based coatings can trap moisture and corrosive elements between the metal and the coating. Lanolin-based seems preferred. I use FF on select underbody components and wash the undercarriage during season. GL
 
I'd love to use FF as preventative maintenance, but it's hard to get underneath. If I ever do the planned 1" lift, that may be the difference.
 

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