37 complaints reported

2004 Toyota 4Runner Suspension

Owner-reported problems and safety issues filed with NHTSA. Review common failures, severity levels, and complaint trends over time.

Reports
37
Crashes
0
Fires
0
Injuries
0

Complaint Timeline

Chronological view of owner reports

Aug 2024

I recently bought a 2004 Toyota 4 Runner and the frame of the vehicle has significant corrosion to the extent of holes, weld failures and more. I've never seen frame rust so bad on a vehicle like this. I'm a little uneasy about the safety of this situation. I think Toyota should replace the frame or give a good discount on the part and labor. I hope someone can help me out with this concern.

Type: Vehicle, Vehicle: 2004 TOYOTA 4RUNNER, Manufacturer: Toyota Motor Corporation
Incident: Aug 2024
Dec 2023

Excessive frame rusting. There are holes in the frame from rusting. At this point in time there isn’t anything I can do about the issues. Frame is unrepairable.

Type: Vehicle, Vehicle: 2004 TOYOTA 4RUNNER, Manufacturer: Toyota Motor Corporation
Incident: Dec 2023
Oct 2023

Frame rusted through on left rear of vehicle were suspension parts are attached.

Type: Vehicle, Vehicle: 2004 TOYOTA 4RUNNER, Manufacturer: Toyota Motor Corporation
Incident: Oct 2023
Jun 2023

Frame is falling apart rusted right out unsafe to drive a truck I'm making payments on.

Type: Vehicle, Vehicle: 2004 TOYOTA 4RUNNER, Manufacturer: Toyota Motor Corporation
Incident: May 2023
Apr 2023

I have. Toyota 4Runner the frame is very rusty I ask the. Dealer few times for recall and he said no. Recall. It is very dangerous to drive. The buddy is very nice just the frame is very rusty. Want ca I do need help

Type: Vehicle, Vehicle: 2004 TOYOTA 4RUNNER, Manufacturer: Toyota Motor Corporation
Incident: Apr 2018
Jul 2022

Complete frame rust-out. Suspension at rear axle disintegrated. Vehicle undriveable. My son had just taken the vehicle (moving his belongings) from Minnesota to the East Coast and back. No problems or issues. After returning, while driving the vehicle I had a hard braking event which is when I noticed something was drastically wrong. This frame failure really snuck up on us. We were lucky, no accident or incidents occurred.

Type: Vehicle, Vehicle: 2004 TOYOTA 4RUNNER, Manufacturer: Toyota Motor Corporation
Incident: Sep 2021
Jun 2022

My Car was inspected by a Virginia Inspection Station and was cited for significant rust holes in the frame which have to be repaired. The frame should not have such significant rust that it needs to be fixed or it will be a hazard on the road. Based on other litigation around Toyota fames from this period of time is seems that this is a systemic issue and should be made to provide a recall based on the safety risk that is present with a frame failure as noted in previous class-action lawsuits. The Brian Warner et al. v. Toyota Motor Sales, U.S.A., Inc., Class Action Settlement (UNITED STATES DISTRICT COURT FOR THE CENTRAL DISTRICT OF CALIFORNIA Case No. 2:15-cv-02171-FMO-FFM) is a perfect example of the risk to the public if this is not corrected.

Type: Vehicle, Vehicle: 2004 TOYOTA 4RUNNER, Manufacturer: Toyota Motor Corporation
Incident: Apr 2022
May 2022

The contact owns a 2004 Toyota 4Runner. The contact stated that he noticed that the tow hitch had separated from the frame and was laying on the ground. The contact stated upon inspecting the subframe of the vehicle, he noticed that the subframe to which the radiator mount was attached was severely corroded. The contact stated that upon changing the oil in the vehicle he noticed that the front passenger’s side subframe had a significant size hole. The dealer was not notified of the failure. The vehicle was not diagnosed or repaired. The manufacturer was notified of the failure and provided case numbers to the contact. The failure mileage was approximately 224,000. The contact stated that their vehicle is not a part of the recall that affects other Toyota models although other 4Runners have experienced similar issues. It was recommended to the contact to sell or trade-in their vehicle. No repairs were made.

Type: Vehicle, Vehicle: 2004 TOYOTA 4RUNNER, Manufacturer: Toyota Motor Corporation
Incident: May 2019
Apr 2022

vehicle failed inspection due to hole in frame-- 08/14/20-- had to cover repairs--under body has severe frame damage from rust--toyota recalled and replaced truck frames from bad steel on 2004 tacomas but not to the 2004 4runners

Type: Vehicle, Vehicle: 2004 TOYOTA 4RUNNER, Manufacturer: Toyota Motor Corporation
Incident: Aug 2020
Mar 2022

The entire frame is rusted. It's been welded back together on 2 different occasions. The last time it happened I was pulling out of driveway and the vehicle cannot be steered at all. I live in east TN and should not have a rusted frame. This is not an isolated problem. This is a problem with the 4runners and should be recalled. There are literally 1,000's of 4runners with Rusty frames. I don't understand why this isn't being recalled. You can reach me at [XXX] or [XXX]. INFORMATION Redacted PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6).

Type: Vehicle, Vehicle: 2004 TOYOTA 4RUNNER, Manufacturer: Toyota Motor Corporation
Incident: Dec 2022
Mar 2022

2004 Toyota 4Runner, original owner with roughly 210K miles. We took the vehicle to the mechanic concerning a sway bar issue. He informed us that the frame of the vehicle was nearly rusted into and that it's serious safety issue to continue to drive it. It is my understanding the Toyota recalled several other models with this same issue but did not include the 4Runner in this recall.

Type: Vehicle, Vehicle: 2004 TOYOTA 4RUNNER, Manufacturer: Toyota Motor Corporation
Incident: Mar 2022
Sep 2021

Extensive rust on frame and suspension parts. Areas completely rusted through, presenting safety hazard.

Type: Vehicle, Vehicle: 2004 TOYOTA 4RUNNER, Manufacturer: Toyota Motor Corporation
Incident: Jan 2021
May 2021

The frame rusted and at least two parts of the frame rusted through. Informed by the mechanic upon state inspection. On or around October 18, 2021

Type: Vehicle, Vehicle: 2004 TOYOTA 4RUNNER, Manufacturer: Toyota Motor Corporation
Incident: Oct 2021
Feb 2021

The control arms rusted completely off the frame. The whole frame has rust holes!

Type: Vehicle, Vehicle: 2004 TOYOTA 4RUNNER, Manufacturer: Toyota Motor Corporation
Incident: Jan 2021
Oct 2020

TL* THE CONTACT'S SON OWNS A 2004 TOYOTA 4RUNNER. THE CONTACT STATED THAT WHILE HIS SON WAS DRIVING 15 MPH, HIS SON HEARD A LOUD POPPING SOUND AS THE REAR AXLE TRAILING ARM FELL OFF THE VEHICLE WITHOUT WARNING. DUE TO THE FAILURE, THE CONTACT HAD THE VEHICLE TOWED TO AN INDEPENDENT MECHANIC. THE MECHANIC PLACED THE VEHICLE ON A HOIST, AND DEEMED THE VEHICLE UNSAFE TO DRIVE DUE TO SEVERE CORROSION TO THE UNDERCARRIAGE. THE CONTACT THEN HAD THE VEHICLE TOWED BACK TO HIS RESIDENCE. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS APPROXIMATELY 104,000.

Type: Vehicle, Vehicle: 2004 TOYOTA 4RUNNER, Manufacturer: Toyota Motor Corporation
Incident: Sep 2020
Oct 2020

THE FRAME HAS COMPLETELY RUSTED

Type: Vehicle, Vehicle: 2004 TOYOTA 4RUNNER, Manufacturer: Toyota Motor Corporation
Incident: Oct 2020
Aug 2020

VEHICLE FRAME IS SEVERELY CORRODED AND IS UNSAFE TO DRIVE.

Type: Vehicle, Vehicle: 2004 TOYOTA 4RUNNER, Manufacturer: Toyota Motor Corporation
Incident: Aug 2020
Apr 2020

TODAY I FAILED VEHICLE INSPECTION BECAUSE OF RUST AND DETERIORATION OF MY CHASSIS FRAME. THE VEHICLE WAS BOUGHT NEW, SELDOM DRIVEN IN ANY AREAS OF SALTED OR SANDED ROADS. IT WAS ALSO MOSTLY GARAGED EITHER AT WORK AND/OR AT HOME. THE VEHICLE ONLY HAS 175000 WHICH IS LOW CONSIDERING THE AGE OF THE VEHICLE. I KNOW THAT MANY TOYOTAS HAVE HAD THIS PROBLEM AND SOME MODELS HAVE HAD RECALLS. IN SPITE OF THE MANY PROBLEMS THAT FORERUNNERS HAVE HAD, IT IS YET TO BE RECALLED....AND ALL RECALLS START AT 2005. MINE IS A 2004 AND THE FRAME IS FALLING APART. I AM EXTREMELY DISAPPOINTED AND WISH VEHICLES IN MY DEMOGRAPHICS WOULD BE CONSIDERED IN A NEW RECAL......

Type: Vehicle, Vehicle: 2004 TOYOTA 4RUNNER, Manufacturer: Toyota Motor Corporation
Incident: Apr 2020
Sep 2019

FRAME RUST IN 2 AREAS; MECHANIC DEEMED UNSAFE TO DRIVE

Type: Vehicle, Vehicle: 2004 TOYOTA 4RUNNER, Manufacturer: Toyota Motor Corporation
Incident: May 2019
Sep 2019

'FRAME RUST' FRAME RUSTED IN 2 AREAS AND MECHANIC DEEMED UNSAFE TO DRIVE.

Type: Vehicle, Vehicle: 2004 TOYOTA 4RUNNER, Manufacturer: Toyota Motor Corporation
Incident: May 2019
Sep 2019

FRAME AND SUSPENSION RUST HAS WEAKENED THE PARTS TO THE POINT OF FAILURE. REAR UPPER CONTROL ARM MOUNTING BRACKET ON REAR AXLE BROKE WHILE DRIVING ON HIGHWAY WHILE GOING AROUND A TURN. VEHICLE'S REAR WOBBLED BACK AND FORTH VIOLENTLY. I ALMOST LOST CONTROL OF THE VEHICLE. THERE ARE OTHER PIECES THAT LOOK CLOSE TO FAILURE.

Type: Vehicle, Vehicle: 2004 TOYOTA 4RUNNER, Manufacturer: Toyota Motor Corporation
Incident: Jun 2019
May 2019

FRAME HAS ROTTED AND HAS BEEN DECLARED UNSAFE TO DRIVE.

Type: Vehicle, Vehicle: 2004 TOYOTA 4RUNNER, Manufacturer: Toyota Motor Corporation
Incident: Jul 2018
Mar 2019

EXCESSIVE FRAME ROT/RUST

Type: Vehicle, Vehicle: 2004 TOYOTA 4RUNNER, Manufacturer: Toyota Motor Corporation
Incident: Mar 2019
Mar 2019

WAS DRIVING TO WORK GOING 50 MPH BRAKED TO COME TO A STOP AND THE BACK END STARTED TO TURN ALMOST HAD AN ACCIDENT. FRAME IS COMPLETELY RUSTED OUT. TOO DANGEROUS TO DRIVE.

Type: Vehicle, Vehicle: 2004 TOYOTA 4RUNNER, Manufacturer: Toyota Motor Corporation
Incident: Mar 2019
Sep 2018

TAKATA RECALL THIS YEAR THE EXACT SAME FRAMES WERE REPLACED ON THE TOYOTA TACOMA. MY FRAME AND CROSS MEMBERS ARE RUSTED OUT ON THE FRONT END AND THIS HAS BEEN GARAGE KEPT AND ONLY HAS 92K MILES. MY 4RUNNER SHOULD NOT HSVE THIS MUCH RUST ON THE FRAME, AFTER IT HAS BEEN METICULOUSLY TAKEN CARE OF.

Type: Vehicle, Vehicle: 2004 TOYOTA 4RUNNER, Manufacturer: Toyota Motor Corporation
Incident: Feb 2012

Trend Over Time

Complaints by year

Quick Summary

The 2004 Toyota 4Runner has 37 Suspension complaints on file. Review the timeline above for detailed owner experiences.