2004 Toyota 4Runner UNKNOWN OR OTHER

The body frame on this vehicle is almost completely rushed out. I don’t know what to do. If I should have the frame replaced I know there’s been a couple recalls on similar Toyota models.

Rusting frame, no specific incident date. Used today’s date.

Excessive frame and suspension corrosion that could lead to serious accidents if not repaired at a very high cost for myself

Underbody of vehicle is rusting away from vehicle body, I was made aware of situation at a service appointment in April of 2022, no vehicle collision or wreck has happened because of it yet,

I own a 2004 Toyota 4runner Sport Edition that suffers from frame rust issues. Mine isn't as bad as I've seen in person while working at a Toyota dealership as a tech or on the forums but from my experience in assisting in replacing frames at the dealership I know that my frame won't last very long. When I bought it from the original owner it had around 86,XXX miles on it and the typical spot in the from was rusted out. I choose to purchase it because it was the best example I could find, others having worse rust. I quickly discovered a weak spot which became a hole when trying to jack it up to do work along with chunks of rust that came off the rear end of the frame and all over. The weak spot that ended up being a hole seems to be caused by the AC drain location and how it drips right onto the frame which has an opening right by where it drips. I believe the drips went into the frame through the factory hole and lead to the weak spot and hole in my frame. I am not the only one who has experienced this issue. In fact on a Toyota 4runner forum there is threads on people extending the drain to prevent the same thing from happening to theirs or from getting worse. As a former Toyota tech who has seen how bad the frames that came in under recall and 4runner frames were first hand I cant believe that a the 4runner frames weren't included in the recalls. I've seen countless threads/reviews/complaints of severe rust causing accidents from suspension components. Toyota should be held accountable for the rust issues ont he 4runners just like the other vehicles. My 4runner now has 113,xxx on it and it will rust out long before the drivetrain gives out no matter what I try to do. My only option is to fix it using safe t caps when the time comes who makes frame fixes for Tacomas, Tundras, FJ crusier and of course the 4runner. They produce them for these vehicles because the frames rust out pre maturely. The rusty 4runner frames are a safety issue and should be addressed.

The right rear control arm mount completely rusted away from the frame. Causing it to start fish-tailing out of control. Also there are other mounts that have rusted through. Like for instance, the gas tank strap mounted to the frame. There are also more areas of the frame that are rusting through. I'm just glad that I was the only one in the vehicle and going slow enough to not cause an accident. I then took it to an auto repair shop and they informed me that the frame on my vehicle has many problem areas of being rusted through. I have attached some photos of the problem areas taken from the repair shop.

2004 Toyota 4 runner frame is corroded so bad and dealer mechanic thinks it is a default of manufacturer and suggested I file a complaint with you. He said many Toyota 4 runners having same issue and it is a safety hazzard.

The frame of the vehicle has rusted so badly the Toyota Dealer I have taken to for diagnosis and repairs refuses to put the vehicle on their lift to inspect or work on the underside of the car for fear of the safety of their workers. This is not a new problem for Toyota because they have lost a civil suit for premature rusting of the frames on other truck models. I took my 4Runner to a frame repair shop and got an estimate. I don't have the funds to do the repair. If the repairs were not made I could continue to drive it until the frame breaks I was told. When the frame breaks it's indeterminable, how many individuals could be injured? My hope when the frame breaks I don't lose control so I won't be killed or severely injured and any others that could be involved in the accident don't get harmed either. There has been a class-action lawsuit initiated where my 4Runner would be included in this suit. Toyota needs to be held accountable for a poorly designed and manufactured frame. I demand Toyota replace/repair the frame on my 4Runner so that it can be safely driven to the end of life of the engine and transmission before persons are harmed from a frame failure. Inver Grove Toyota first informed me the frame had holes rusted in it on November 19, 2019. Then, on Dec 20, 2019, they informed me it was unsafe to lift. I can supply copies of 3 repair invoices where the dealer made note of the corroded frame.

Frame rust discovered by state inspection mechanic, vehicle fails for frame members rusted through. May not be repairable.

The frame on my 4Runner is severely rusted out; it is available to be inspected if requested. When I'm driving, the vehicle is potentially unstable due to frame rot which could cause potentially life threating injuries to myself, my passengers, and others on the road. The problem has been confirmed by JR Autohaus in Woburn MA. The vehicle has not been inspected by the manufacturer/police/or insurance companies. There was no prior indication of an issue; it appeared when the vehicle was put on a lift to have a new exhaust put on: the vehicle was creaking and was dangerous to be on the lift for the technician. He inspected the frame and took pictures of the rust damage. The issue was discovered on 3/23/21

MY VEHICLE HAS SEVERE FRAME ROT, ALL OF WHICH COMING FROM THE FACTORY WELDS TO THE SURFACE POINTS ALONG WITH IT'S ROTTING FROM THE INSIDE OUT ESPECIALLY AROUND THE FRONT LOWER CONTROL ARM AREAS OF THE DRIVER AND PASSENGER SIDES OF THE VEHICLE. THIS ALSO REACHING THE BACK OF THE VEHICLES FRAME TOO.

WHILE HAVING THE TIRES REPLACED, THE MECHANICS WERE UNABLE TO LOWER THE SPARE TIRE. AFTER CALLING FOR BACKUP THE MECHANICS WERE ABLE TO CUT THE TIRE FROM THE VEHICLE. THIS WAS BEFORE A TRIP TO ATLANTIC CITY, SO I HAD TOYOTA REPLACE THE HOIST AT MY COST TO REPAIR (UNWARE OF THE RUST AND FRAME ISSUES). THE 4RUNNER WAS APPROXIMATELY 12 YEARS OLD WHEN THE PROBLEM WAS IDENTIFIED. I DO NOT KNOW HOW LONG THE HOIST WAS BAD BEFORE THAT DATE BECAUSE I NEVER HAD TO USE THE HOIST. THE HOIST WAS COMPLETELY RUSTED. I'M REPORTING THIS NOW SO THAT OTHER OWNERS CAN CHECK THEIR HOIST AND FRAMES. THE FRAMES ARE DANGEROUS (RUSTED AND FALLING APART) AND WILL EVENTUALLY BE THE CAUSE OF SOMEONE'S ACCIDENT AND POTENTIAL DEATH. I'VE CONTACTED MY STATE SENATOR TO LOOK INTO THE FRAME INVESTIGATION AND WHY IT IS TAKING SO LONG. HOPEFULLY, I WILL HEAR BACK SOON. TOYOTA'..SHAME ON YOU FOR NOT WARNING OWNERS AND MAKING THIS RIGHT.

DASHBOARD SINGLE LINE CRACK FROM DRIVER'S SIDE CONTINUOUS THROUGH HALFWAY INTO THE PASSENGER'S SIDE.

THIS 2004 4RUNNER WAS PURCHASED FROM A LOCAL DEALER IN SOUTH FLORIDA. THE CARFAX REPORT STATES THAT IT WAS PREVIOUSLY TITLED IN TEXAS AND THEN LATER IN NEW YORK. IT DID PASS THE NEW YORK STATE SAFETY INSPECTION IN 2020. HOWEVER, AFTER OWNING THE VEHICLE FOR A SHORT PERIOD I TOOK IT TO A MECHANIC FOR A OIL CHANGE. I WAS ADVISED THAT THE RUST/CORROSION ON THE FRAME AND UNDERBODY COMPONENTS WAS QUITE SEVERE. MY CONCERN IS THAT IT MAY WORSEN AND AFFECT THE OVERALL SAFETY OF THE TRUCK AS WELL AS THE RESALE VALUE. I'M AWARE THAT TOYOTA HAD A SIMILAR ISSUE WITH TACOMA'S, TUNDRA'S, AND SEQUOIA VEHICLES. WHY WASN'T THE 4RUNNER INCLUDED IN THESE RECALLS GIVEN THE LARGE AMOUNT OF COMPLAINTS REGARDING 2003-2009 MODELS?

RE: NHSTA ACTION # DP18002. I OWN A 2004 TOYOTA 4RUNNER AND HAVE HAD PROBLEMS SIMILAR TO THOSE NOTED IN THE REFERENCED CASE. UPON READING THE CASE DETAILS I INVESTIGATED MY 4RUNNER AND FOUND SIMILAR SERIOUS STRUCTURAL CORROSION PROBLEMS. I CONSULTED WITH A LOCAL VIRGINIA MOTOR VEHICLE STATE INSPECTOR AND LEARNED THAT THE CORROSION WAS SO SEVERE, THE VEHICLE WOULD NOT PASS INSPECTION AND BE LEGALLY, OR SAFELY, DRIVEN. I HAD THIS DAMAGE REPAIRED, AT SIGNIFICANT COST TO MYSELF, TO RETURN THE VEHICLE TO USABLE AND TRUSTWORTHY CONDITION. I WRITE IN SUPPORT OF THE REFERENCE CASE. PLEASE KEEP ME INFORMED OF ANY PROGRESS IN THIS CASE. THE "WHEN DID THIS HAPPEN DATE" IS THE DATE OF DISCOVERY.

AFTER CHECKING UNDER MY 2004 4RUNNER FOR A FAULTY FOG LIGHT CONNECTION I NOTICED A LOT OF RUST ON THE FRONT FRAME. AFTER FURTHER INVESTIGATION I FOUND IT TO BE COMPLETELY RUSTED THROUGH. THERE ISN'T MUCH HOLDING THE BUMPER ON THERE

VEHICLE HAS DEVELOPED SEVERE RUST HOLES IN THE FRAME, SUFFICIENT TO FAIL NY STATE INSPECTION. HOLES HAVE APPEARED, AND THE METAL AROUND THE HOLES IS ALSO SOFT DUE TO RUST. THIS WAS BROUGHT TO OUR ATTENTION WHEN WE BOUGHT THE CAR OUT OF STATE, REGISTERED IT IN NY, AND THE VEHICLE FAILED ON UNSAFE FRAME RUST.

MY 2004 TOYOTA 4RUNNER HAS DANGEROUS FRAME RUST PERFORATION. TOYOTA SOMEHOW WAS ALLOWED TO EXCLUDE 4RUNNERS, WHEN THEY WERE MADE TO REPLACE FRAMES ON SEQUOIA, TUNDRA, TACOMA, AND TACOMA TRUCKS OF SIMILAR VINTAGE. THERE IS NO REASON THAT IS FAIR NOR EQUITABLE TO 4RUNNER OWNERS BE DENIED FRAME REPLACEMENTS WHEN ALL OTHER TOYOTA TRUCKS WERE GRANTED IN THE SETTLEMENT

2004 TOYOTA 4RUNNER, THE FRAME IS RUSTED REALLY BAD. CAN'T LIFT IT WITH A HOIST AND PARTS THAT CONNECT TO IT FOR SUSPENSION ARE RUSTED AS WELL. NOT GOOD IF YOU HIT A BUMP AND IT BREAKS, COULD CAUSE A SERIOUS ACCIDENT.

COMPLETE FRAME IS RUSTED OUT

THERE IS A CRACK IN FRAME ON PASSENGER SIDE NEVER IN ACCIDENT . THE RUST CORROSION IS HORRIBLE ALMOST CRACKED ALL THE WAY ON DRIVERS SIDE ,FRONT HOOKS GONE FROM RUST.

FRAME RAIL ROTTING AND I'VE ALWAYS PARKED IN A GARAGE!

A THIN METAL SUPPORT PLATE WELDED TO REAR AXLE CONNECTS UPPER CONTROL ARMS TO REAR AXLE. BOTH SUPPORT PLATES TOTALLY DISINTEGRATED FROM RUST. THESE PLATES ARE A STRUCTURAL COMPONENT OF VEHICLE SUSPENSION SYSTEM. WHEN THE UPPER CONTROL ARMS FAILED FROM FAILED SUPPORT PLATES, THE BRAKE WARNING LIGHT CAME ON. THE BRAKE LINE HAD BEEN DAMAGED MOST LIGHTLY FROM BRAKE LINE BEING HIT BY CONTROL ARM. THE MOTION/LOUD NOISE OF DETACHED CONTROL ARMS CONTACTING METAL AXLE WAS FOLLOWED BY BRAKE LIGHT COMING ON. WITHIN 2 YEARS OF PURCHASE OF AUTOMOBILE CHASSIS RUST WAS NOTICEABLE AND COMMENTED BY MECHANICS. WHEN CONFRONTING TOYOTA, THEIR SAME COMMENT OF NOT BEING UNDER WAURANTY PREVAILED. THE LAST TIME I CONTACTED THEM I ASKED TO SPEAK TO THEIR ENGINEERS BECAUSE I FELT THE SUPPORT PLATE DESIGN IS UNSAFE AND TO THICKEN THE PLATE WOULD BE A SMALL EXPENSE. THE VEHICLE WAS IN MOTION WHEN THE SUPPORT PLATES FRACTURED. THEY TOLD ME I COULD TALK TO ANYONE ELSE OTHER THAN THEIR SUPPORT LINE AND THAT THE PLATE WOULD NOT BE CHANGED. I AM A DEGREED ENGINEER WITH A BACHELORS AND TWO MASTERS IN ENGINEERING AND AM DISAPPOINTED IN HOW THEY VALUE PENNIES OVER AN OBVIOUS SAFETY ISSUE. BEST REGARDS MY NAME AND PHONE ARE (XXXX) PHONE (XXXX) IF YOU WOULD LIKE TO DISCUSS. PARTS OF THIS DOCUMENT HAVE BEEN REDACTED TO PROTECT PERSONALLY IDENTIFIABLE INFORMATION PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

TOOK MY 2004 TOYOTA 4RUNNER IN FOR A BRAKE JOB AND THE MECHANIC ASKED IF THEIR WAS ANY RECALLS ON OUR VEHICLE FOR RUSTED FRAME .HE SAID THAT WE WERE GOING TO HAVE TROUBLE WITH IT SOON DO TO FRAME RUSTING SO BAD

FRAME FOUND TO BE RUSTING AWAY AND CAN NOT BE SAFELY INSPECTED. WAS TOLD BY SAFETY MECHANIC AREAS ARE VERY BAD AND PARTS MAY START FALLING OFF.