AFTER NOTICING A STRONG GEAR OIL ODOR AND SEEING THE ACTUAL GEAR OIL ON THE BACK THE OF THE VEHICLE I WAS ALARMED TO FIND OUT THAT THE REAR AXLE HOUSING HAD RUST PERFORATING THE REAR OF THE HOUSING. ONCE THE HOUSING WAS CHECKED BY A CERTIFIED MECHANIC AND TURNED AWAY DUE TO FEAR OF DESTROYING THE HOUSING, I REMOVED THE VEHICLE …
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AFTER NOTICING A STRONG GEAR OIL ODOR AND SEEING THE ACTUAL GEAR OIL ON THE BACK THE OF THE VEHICLE I WAS ALARMED TO FIND OUT THAT THE REAR AXLE HOUSING HAD RUST PERFORATING THE REAR OF THE HOUSING. ONCE THE HOUSING WAS CHECKED BY A CERTIFIED MECHANIC AND TURNED AWAY DUE TO FEAR OF DESTROYING THE HOUSING, I REMOVED THE VEHICLE FROM THE ROAD. *TR
NHTSA ODI #10474018
44,700 miles · Apr 11, 2012
Power Train
REAR DIFFERENTIAL RUST THROUGH. *TR
NHTSA ODI #10454833
141,000 miles · Jul 10, 2011
Power Train
2002 4RUNNER SR5 4WD, 141K MILES, COMPLETELY RUSTED THROUGH REAR DIFFERENTIAL, BOTH REAR AXLE SEALS BUSTED OUT, DIFFERENTIAL HOUSING HAS SEVERAL PIN HOLE LEAKS AND IS THINNED OUT, THE ONLY FIX IS A COMPLETELY NEW REAR END, WHICH IS VERY COSTLY, I AM THE 2ND OWNER, I'VE OWNED A 99 4RUNNER THAT HAD THESE SAME REAR DIFFERENTIAL RUS…
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2002 4RUNNER SR5 4WD, 141K MILES, COMPLETELY RUSTED THROUGH REAR DIFFERENTIAL, BOTH REAR AXLE SEALS BUSTED OUT, DIFFERENTIAL HOUSING HAS SEVERAL PIN HOLE LEAKS AND IS THINNED OUT, THE ONLY FIX IS A COMPLETELY NEW REAR END, WHICH IS VERY COSTLY, I AM THE 2ND OWNER, I'VE OWNED A 99 4RUNNER THAT HAD THESE SAME REAR DIFFERENTIAL RUST ISSUES, THE RUST IS RIDICULOUS AND HAS DETERIORATED THE WHOLE UNDERCARRIAGE AND MY 4RUNNER IS GARAGE KEPT AND I WASH IT ALL THE TIME. I CAN'T BELIEVE TOYOTA HAS NOT BEEN HELD ACCOUNTABLE FOR THE RUSTING OUT OF REAR DIFFERENTIALS AND REAR AXLE ISSUES. *TR
NHTSA ODI #10411676
158,000 miles · Jul 3, 2011
Power Train
THE REAR DIFFERENTIAL HOUSING HAS RUSTED THROUGH CAUSING ITS OIL TO LEAK OUT. *TR
NHTSA ODI #10410344
100,000 miles · May 9, 2011
Power Train
2002 TOYOTA 4 RUNNER RUSTED OUT REAR AXLE HOUSING. REAR AXLE HOUSING LEAKS OIL DUE TO RUST EROSION ON THE REAR AXLE COVER. *TR
NHTSA ODI #10399713
Mileage unknown · Sep 20, 2010
Power Train
TL* THE CONTACT OWNS A 2002 TOYOTA 4RUNNER. THE CONTACT STATED WHILE DRIVING 35 MPH, THE VEHICLE BEGAN TO LOSE POWER ABNORMALLY ACCOMPANIED BY THE ILLUMINATION OF THE CHECK ENGINE WARNING LIGHT. THE CONTACT LATER DISCOVERED THAT THE ALUMINUM RADIATOR AND THE BOLT THAT CONNECTED THE COOLANT AND TRANSMISSION FLUID TRANSFER WAS FAU…
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TL* THE CONTACT OWNS A 2002 TOYOTA 4RUNNER. THE CONTACT STATED WHILE DRIVING 35 MPH, THE VEHICLE BEGAN TO LOSE POWER ABNORMALLY ACCOMPANIED BY THE ILLUMINATION OF THE CHECK ENGINE WARNING LIGHT. THE CONTACT LATER DISCOVERED THAT THE ALUMINUM RADIATOR AND THE BOLT THAT CONNECTED THE COOLANT AND TRANSMISSION FLUID TRANSFER WAS FAULTY CAUSING THE TWO FLUIDS TO COMBINE ABNORMALLY. THE CONTACT STATED SPOKE WITH SEVERAL MECHANICS THAT ADVISED HIM OF THAT THE TWO FLUIDS WERE COMBINING. THE VEHICLE WAS NOT REPAIRED. THE CURRENT AND FAILURE MILEAGE WAS UNAVAILABLE.
NHTSA ODI #10356528
74,600 miles · Feb 3, 2010
Power Train
I AM THE ORIGINAL OWNER OF A 2002 TOYOTA 4RUNNER-SR5, SPORT EDITION WITH 74,600K MILES. IN NOVEMBER 2009, I EXPERIENCED THE SAME PROBLEM THAT'S BEING REPORTED BY OTHER TOYOTA OWNERS WHOSE VEHICLES ARE BEING RECALLED. THE ACCELERATOR PEDAL STUCK IN A PARTIALLY DEPRESSED POSITION ON ITS OWN AND QUITE SUDDENLY. THIS OCCURRENCE ON…
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I AM THE ORIGINAL OWNER OF A 2002 TOYOTA 4RUNNER-SR5, SPORT EDITION WITH 74,600K MILES. IN NOVEMBER 2009, I EXPERIENCED THE SAME PROBLEM THAT'S BEING REPORTED BY OTHER TOYOTA OWNERS WHOSE VEHICLES ARE BEING RECALLED. THE ACCELERATOR PEDAL STUCK IN A PARTIALLY DEPRESSED POSITION ON ITS OWN AND QUITE SUDDENLY. THIS OCCURRENCE ONLY HAPPENED ONCE. THE ENGINE WAS RACING AT A VERY HIGH RPM AND MY REAR TIRES WERE SQUEALING LOUD ENOUGH TO DRAW ATTENTION FROM PASSERSBY. LUCKILY FOR ME I WAS SLOWLY PULLING INTO A PARKING SLOT. MY REACTION TO THIS SITUATION WAS TO PUT THE GEAR IN NEUTRAL AND APPLIED THE BRAKES. MY MAIN CONCERN IS IF THE ONGOING INVESTIGATION BY THE NHTSA AND TOYOTA WILL INCLUDE A LOOK-BACK AT EARLIER MODELS FOR THESE KNOWN PROBLEMS? AND, IF SO, WHAT IS THE MANUFACTURER'S RECOMMENDATION TO OWNERS' WITH EARLIER MODELS? *TR
NHTSA ODI #10304936
90,000 miles · May 11, 2009
Power Train
I HAVE A 2002 TOYOTA 4 RUNNER WITH RUST OUT OF THE REAR DIFFERENTIAL HOUSING. I TOOK THE VEHICLE IN FOR REPAIRS ONLY TO DISCOVER THAT METAL WAS QUITE RUSTED AT THE REAR HOUSING AND INSTEAD OF A SIMPLE PART REPLACEMENT, THE WHOLE ASSEMBLY HAS TO BE REPLACED, A COSTLY REPAIR. I FOUND OTHER OWNERS WITH SIMILAR STORIES ONLINE. IS TH…
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I HAVE A 2002 TOYOTA 4 RUNNER WITH RUST OUT OF THE REAR DIFFERENTIAL HOUSING. I TOOK THE VEHICLE IN FOR REPAIRS ONLY TO DISCOVER THAT METAL WAS QUITE RUSTED AT THE REAR HOUSING AND INSTEAD OF A SIMPLE PART REPLACEMENT, THE WHOLE ASSEMBLY HAS TO BE REPLACED, A COSTLY REPAIR. I FOUND OTHER OWNERS WITH SIMILAR STORIES ONLINE. IS THIS A DEFECTIVE PART? I HAD TEMPORARY REPAIR WITH GRINDING, WELDING AND EPOXY WHICH FOR THE TIME BEING HAS CORRECTED THE LEAK BUT EVENTUALLY IT WILL REAPPEAR. *TR
NHTSA ODI #10268349
95,500 miles · Aug 2, 2008
Power Train
CHECK ENGINE LIGHT CAME IN, IT WAS DIAGNOSED AS A 770 SHIFT SOLENOID-E AND I WAS TOLD BY TWO DIFFERENT EXPERTS THAT MY TRANSMISSION WOULD NEED TO BE REPLACED. THE TOYOTA 4-RUNNER WAS PURCHASED IN JANUARY 2008 FROM FOLSOM LAKE TOYOTA WITH 89,000 MILES AND CURRENTLY HAS 95,500 MILES ON IT. THE ESTIMATE FOR REPAIR WAS $2,300.00. …
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CHECK ENGINE LIGHT CAME IN, IT WAS DIAGNOSED AS A 770 SHIFT SOLENOID-E AND I WAS TOLD BY TWO DIFFERENT EXPERTS THAT MY TRANSMISSION WOULD NEED TO BE REPLACED. THE TOYOTA 4-RUNNER WAS PURCHASED IN JANUARY 2008 FROM FOLSOM LAKE TOYOTA WITH 89,000 MILES AND CURRENTLY HAS 95,500 MILES ON IT. THE ESTIMATE FOR REPAIR WAS $2,300.00. *TR
ON CERTAIN SPORT UTILITY VEHICLES, DUE TO A MANUFACTURING ISSUE IN THE FRONT SUSPENSION LOWER BALL JOINT, THERE IS A POSSIBILITY THAT THE SURFACE OF THE BALL OF THE JOINT MAY HAVE BEEN SCRATCHED. THE BALL JOINT MAY EVENTUALLY EXPERIENCE EXCESSIVE WEAR AND LOOSENESS, RESULTING IN INCREASED STEERING EFFORT.
Consequence & remedy
Consequence: THE LOWER BALL JOINT MAY SEPARATE FROM THE KNUCKLE CAUSING LOSS OF STEERING CONTROL AND A CRASH COULD OCCUR.
Remedy: DEALERS WILL REPLACE THE FRONT SUSPENSION LOWER BALL JOINTS FREE OF CHARGE. THE RECALL BEGAN ON JULY 5, 2005. OWNERS MAY CONTACT TOYOTA AT 1-800-331-4331.
Model-level recall history does not show whether a particular VIN is affected or has received a repair. Check a VIN with NHTSA ↗
NHTSA investigations
1
DP18002 · Frame Corrosion
Opened Aug 17, 2018 · Closed Mar 18, 2022
Status: closed (inferred from source dates) · Structure:frame And Members
On August 7, 2018, the Office of Defects Investigation (ODI) received a defect petition from Mr. Gary Weinreich alleging premature frame corrosion failure in model year (MY) 2002 - 2006 Toyota 4Runner vehicles. The petitioner based his request upon a corrosion-related front suspension failure he experienced in his MY 2005 Toyota 4Runner, a class action lawsuit settlement involving other Toyota products, and other complaints of underbody corrosion in Toyota 4Runner vehicles that he found in NHTSA?s online complaint database. The petitioner submitted a complaint to NHTSA documenting his experience (NHTSA ID 11098055). On August 17, 2018, ODI opened DP18-002 to evaluate the petitioner?s request. ODI?s evaluation included information provided by the petitioner regarding his vehicle, facts related to the class action lawsuit cited by the petitioner, and consumer complaint data received by NHTSA regarding underbody corrosion in third and fourth-generation Toyota 4Runner vehicles.The undercarriage of the petitioner?s vehicle exhibited severe corrosion damage indicative of seawater immersion. The vehicle?s service history shows that concerns with underbody corrosion were first noted by a Toyota dealer in a multi-point vehicle inspection performed on April 28, 2011. The invoice for that inspection noted ?severe and excessive amount of rust on the undercarriage and on the drive shaft transmission.? Two years later, on October 21, 2013, another multi-point inspection by a Toyota dealer observed further progression of underbody corrosion damage, noting: ?rust on shocks/struts and other components,? ?rust on exhaust system,? ?both splash shields severely rusted,? and ?undercarriage very rusty.? On July 17, 2017, approximately 10 months prior to experiencing the suspension failure incident, an independent repair facility performing routine oil change and brake maintenance informed the Petitioner of a concern with ?excessive frame corrosion? on his vehicle. The service history, severe general corrosion damage, failure age, and environment do not support the petitioner?s allegation of premature corrosion failure.ODI?s analysis of NHTSA complaint data identified fifteen incidents of front lower control arm failure in fourth-generation Toyota 4Runner sport utility vehicles. Two of the failures, including the petitioner?s vehicle, involve vehicles operated in ocean front communities with continuous exposure to aerosolized marine salts and potential exposure to seawater immersion. The remaining thirteen failures all involved vehicles owned or previously registered in states with the greatest use of deicing salts to treat road surfaces in winter months (?Salt states?). On average, the front lower control arm failures occurred after 13.1 years in service in highly corrosive environments. The failure ages and environments do not support the petitioner?s allegation of premature corrosion failure. NHTSA is authorized to issue an order requiring notification and remedy of a defect if the Agency?s investigation shows a defect in design, construction, or performance of a motor vehicle that presents an unreasonable risk to safety. 49 U.S.C. ?? 30102(a)(9), 30118. Since the information before the Agency is not indicative of a vehicle-based defect, it is unlikely that any investigation opened because of granting this petition would result in an order concerning the notification and remedy of a safety-related defect. Therefore, upon full consideration of the information presented in the petition and the potential risks to safety, the petition is denied. The denial of this petition does not foreclose the Agency from taking further action if warranted or the p
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