2003 Toyota 4Runner Structure

Severe frame rust. 2 large holes on the inside of the frame just back from the front wheels and 2 large holes at the ends of the rear crossmember.

Toyota has had issues with their frames rusting out and the 4th generation 4Runner is not exempt from this issue. My 2003 is requiring extensive work to keep it on the road safely due to frame rust. A recall to replace frames should be in place.

There is major corrosion on the chassis, brake-power steering-transmission lines, and all metal brackets on the frame and engine. The corrosion is so bad there is holes on the chassis. Known issue, many complaints, Toyota Corp. says to keep calling back maybe something will be done in the future. Unable to upload photos!

Severe frame rust, there was a recall for tacomas but 4Runners have the issue just as bad

The contact owns a 2003 Toyota 4Runner. The contact stated that upon taking the vehicle to several independent mechanics for servicing, he was informed that the subframe was significantly corroded and needed to be replaced. The vehicle was not repaired. The dealer was not notified of the failure. The manufacturer was notified of the failure and informed the contact the vehicle was not covered under recall. The failure mileage was approximately 115,000.

The contact owns a 2003 Toyota 4Runner. The contact stated that while the vehicle was at the tire retailer for tire replacement, the technician informed him that the subframe was corroded. The vehicle was then taken to an independent mechanic, who diagnosed that the passenger's side front and rear subframes were severely corroded, as well as the cross member. The mechanic advised the contact to stop driving the vehicle. The dealer was made aware of the failure and informed the contact that there was no recall associated with the VIN. The vehicle was not repaired. The manufacturer was not made aware of the failure. The failure mileage was approximately 165,000.

Extensive rust through out frame, resulting in holes in structural members. Leaving frame in a weak and vulnerable state.

Excessive frame rust causing difficulty to keep vehicle on the road. No warning lamps, I noticed the rust starting years ago, now the rust is so bad that the frame is rusted through causing difficulty steering and loud crunch noises. I contacted Toyota Consumer Affairs explaining the rust concern and asked if I needed to take the vehicle to a dealership for inspection, they said it wasn’t necessary (sounds like they don’t want to admit the existence of a possible manufacturing defect). The vehicle is available for inspection. I feel like I would be doing a disservice to society if I continue to drive this vehicle on public roads due to the danger of injuring a pedestrian or another motorist.

So much rust has developed the frame is literally giving out. Toyota admitted to a rust issue- it’s now a safety issue with this generation of 4Runner. They did a recall on the same frame for Tacoma but not 4Runner.

Vehicle frame has rusted through and has holes affecting structural condition.

Frame has major rust holes towards the front inside next to the catalytic converters. Hoping to get them repaired before frame failure. The frame design is similar to the 2005 to 2015 Tacomas, which experienced similar issues with rust damage causing frame integrity issues. Toyota had a program to replaced those frames, but not for the 4Runners. The issue seems to be caused by certain factory openings in the frame that allow road salt to enter into the frame cavity, and cause the inside to rust. Being next to the catalytic converter, the heat accelerates the rust. On my 4Runner, the issue has gotten worse in the last 2 years. I cannot understand why Toyota covered all other trucks/suvs that use this similar frame but ignored the 4Runner.

The frame on my 4Runner is rusting through in multiple locations. The rear of the frame has already failed and a trailer I was pulling dragged on the road heavily as it failed. Definitely at risk of caving in long before the engine or transmitoo fails.

I have two 2003 Toyotas, a tundra and 4runner. The 4Runners frame is rusting out everywhere including the welds. My mechanic said it was getting to the point that it’s dangerous to drive and if it was in a wreck the frame would likely fail under the stress. My tundra frame from the same year is immaculate. I believe the are similar frames. This is obviously a defect in the production based on my readings and is very common. The investigation was opened in 2018 and its now 2022, when will this get addressed!

Frame rusted to the point the shop won’t fix the brakes and allow me to drive the car. The brake line rusted through since it was attached to the frame and when repairing the brakes they found the frame rusted too bad and coming apart. Looking online this seems to be a common problem with this year Toyota 4Runner.

TL* THE CONTACT OWNS A 2003 TOYOTA 4RUNNER. THE CONTACT STATED THAT THERE WAS FRAME CORROSION ON THE UNDERSIDE OF THE RADIATOR. THE VEHICLE WAS TAKEN TO THE LOCAL DEALER. THE MANUFACTURER WAS INFORMED OF THE FAILURE AND INFORMED THE CONTACT THAT THERE WERE NO OPEN RECALLS FOR THE FAILURE. THE FAILURE MILEAGE WAS APPROXIMATELY 128,000.*DT CONSUMER STATED TWO MAIN SUPPORT AREAS IS SEVERE CORROSION JUST LIKE THE RECALLED TACOMA'S.*JB

The frame on the vehicle is rusting out. If not repaired, serious injury could occur if the frame breaks. A compromised frame could cause serious injury if an accident occurs. The driver side main frame has a gaping hole on the inside and another hole forming underneath that is in close proximity to the larger hole. The entire back cross bar member supporting the bumper is rusting out as well as the front cross bar member. The vehicle was inspected in July 2020 and the dealership said the frame was OK and had plenty of life left in it. After getting a muffler installed at a local independent shop in October 2021, the hole grabbed the attention of the technician. After inspecting, rusty flakes kept falling away.

The frame is rusted very bad and it’s a major safety issue for this type of vehicle I don’t know when it’s going to fall apart. I am sure I am not the only one to have this problem.

Car inspection at a service center revealed advanced rusting of the frame. I was told this could be dangerous.

The frame is completely rusted through and soon will be unable to support the steering, engine or drive train. The problem was confirmed to me by an independent service center that I have used for 10 years and I trust.

SEVERE RUSTING ON THE FRAME. HAS GONE COMPLETELY THROUGH THE FRAME.

The frame has rusted almost completely through near the front upper and lower control arms near the cross member there. The passenger side is so bad the welder I took it too sad he couldn’t repair it without doing the crossmember section and all. The driver side is not at bad but doesn’t look to hot. The crossmember where the radiator sits is also starting to completely rot away

I HEARD THERE'S AN INVESTIGATION ON THESE FRAMES SO MINE IS ROTTING AWAY

TL* THE CONTACT OWNS A 2003 4RUNNER. THE CONTACT STATED THAT WHILE THE VEHICLE WAS BEING REPAIRED, HE WAS INFORMED THAT THE UNDERCARRIAGE AND SUBFRAME OF THE VEHICLE WAS EXTREMELY RUSTED. THE VEHICLE HAD NOT BEEN TAKEN TO A DEALER OR INDEPENDENT MECHANIC TO BE INSPECTED. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 139,000.

IN REFERENCE TO NHTSA ACTION NUMBER: DP18002. MY MECHANIC INFORMED ME THAT MY 2003 4RUNNER IS STARTING TO EXPERIENCE EXCESSIVE CORROSION ON THE FRAME. HE INFORMED ME THAT THIS IS COMMON WITH THIS MODEL. I CONTACTED A BODY SHOP TO INQUIRE ABOUT POSSIBLE SOLUTIONS. I WAS INFORMED THAT THEY GET INQUIRIES ABOUT THE 2003 4RUNNER OFTEN YET THEY DO NOT LIKE WORKING ON THEM AS THE FRAME IS CONSTRUCTED IN SUCH A WAY THAT IT IS DIFFICULT TO ADDRESS THE CORROSION ISSUES. I'M REPORTING THIS TO HELP FACILITATE THE ONGOING INVESTIGATION AND TO INQUIRE ABOUT ANY PROGRESS BEING MADE ON THE INVESTIGATION.

REAR OF THE FRAME IS RUSTED OUT THERE IS A BIG HOLE IN THE SIDE OF THE FRAME. I JUST BOUGHT THIS VEHICLE AN I LOOKED AT IT BEFORE I BOUGHT IT AN LOOKED AT THE FRAME JUST FIGURED MAYBE THE REST OF THE FRAME WOULD BE FINE BUT IT WAS NOT.