MY 2002 TOYOTA 4 RUNNER FAILED MASS STATE INSPECTION DUE TO EMERGENCY BRAKE NOT ENGAGING. I IMMEDIATELY BROUGHT THE VEHICLE TO A LOCAL AUTO SHOP FOR REPAIR. I WAS THEN NOTIFIED BY THE SHOP THAT THE ENTIRE FRAME WAS COMPLETELY ROTTED & UNSAFE TO DRIVE. THEY REFUSED TO DO ANY REPAIR TO THE E-BRAKE UNTIL THE FRAME WAS REPAIRED. I'M…
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MY 2002 TOYOTA 4 RUNNER FAILED MASS STATE INSPECTION DUE TO EMERGENCY BRAKE NOT ENGAGING. I IMMEDIATELY BROUGHT THE VEHICLE TO A LOCAL AUTO SHOP FOR REPAIR. I WAS THEN NOTIFIED BY THE SHOP THAT THE ENTIRE FRAME WAS COMPLETELY ROTTED & UNSAFE TO DRIVE. THEY REFUSED TO DO ANY REPAIR TO THE E-BRAKE UNTIL THE FRAME WAS REPAIRED. I'M DEVASTATED THAT MY WELL CARED FOR VEHICLE , WITH ONLY 130,000 MILES IS NOW UNSAFE TO DRIVE DUE TO FRAME ROT.
NHTSA ODI #11144553
Mileage unknown · Oct 19, 2018
StructureSuspension
THIS IS YET ANOTHER COSTUMER OF THE 4RUNNER 3RD GENERATION COMPLAINING ABOUT THE FRAME RUSTING OUT. THERE NEEDS TO BE RESPONSABILITY FOR THE BAD FRAMES ON THIS YEAR 4RUNNER. MY FRAME HAS HOLES IN THE REAR CONTROL ARM ATTACHMENT AREA AND MORE RUST ALL THROUGHOUT ENTIRE FRAME. I'M DOING ALL I CAN TO KEEP MY FRAME FROM GETTING ANY …
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THIS IS YET ANOTHER COSTUMER OF THE 4RUNNER 3RD GENERATION COMPLAINING ABOUT THE FRAME RUSTING OUT. THERE NEEDS TO BE RESPONSABILITY FOR THE BAD FRAMES ON THIS YEAR 4RUNNER. MY FRAME HAS HOLES IN THE REAR CONTROL ARM ATTACHMENT AREA AND MORE RUST ALL THROUGHOUT ENTIRE FRAME. I'M DOING ALL I CAN TO KEEP MY FRAME FROM GETTING ANY MORE RUST ON IT AND KEEPING IT SAFE TO BE ON THE ROAD. I STRONGLY BELIEVE TOYOTA SHOULD ALSO HAVE A FRAME RECALL FOR THE 4RUNNER LIKE IT DID FOR THE TUNDRA TACOMA AND SEQUOIA FRAMES.
NHTSA ODI #11141413
168,000 miles · Oct 4, 2018
Structure
TL* THE CONTACT OWNS A 2002 TOYOTA 4RUNNER. WHILE THE VEHICLE WAS UNDERGOING ROUTINE SERVICE AT AN INDEPENDENT MECHANIC SHOP, THE TECHNICIAN NOTICED THAT THE FRAME WAS CORRODED THROUGH AND CAUSED THE TAILPIPE TO DETACH. THE VEHICLE WAS NOT TAKEN TO A DEALER. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOT MADE AWARE OF TH…
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TL* THE CONTACT OWNS A 2002 TOYOTA 4RUNNER. WHILE THE VEHICLE WAS UNDERGOING ROUTINE SERVICE AT AN INDEPENDENT MECHANIC SHOP, THE TECHNICIAN NOTICED THAT THE FRAME WAS CORRODED THROUGH AND CAUSED THE TAILPIPE TO DETACH. THE VEHICLE WAS NOT TAKEN TO A DEALER. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 168,000. ..*BF *JB
NHTSA ODI #11133280
242,999 miles · Oct 2, 2018
Structure
I HAVE A 2002 4 RUNNER AND PUT ALMOST $2,800.00 IN IT LAST YEAR FOR A NEW REAR END, NEW TIRES, BECAUSE I FELT IT STILL HAD A TREMENDOUS AMOUNT OF LIFE LEFT IN IT, ONLY TO FIND OUT THAT THE FRAME HAS 2 HOLES IN IT FROM EXCESSIVE RUST. THE DEALERSHIP I TOOK IT TO INFORMED ME THAT THEY WERE CURRENTLY IN THE PROCESS OF REPLACING FR…
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I HAVE A 2002 4 RUNNER AND PUT ALMOST $2,800.00 IN IT LAST YEAR FOR A NEW REAR END, NEW TIRES, BECAUSE I FELT IT STILL HAD A TREMENDOUS AMOUNT OF LIFE LEFT IN IT, ONLY TO FIND OUT THAT THE FRAME HAS 2 HOLES IN IT FROM EXCESSIVE RUST. THE DEALERSHIP I TOOK IT TO INFORMED ME THAT THEY WERE CURRENTLY IN THE PROCESS OF REPLACING FRAMES FOR 2003 - 2009 MODELS. WHEN I ASKED ABOUT THE 2002 MODELS, THEY STATED THAT TOYOTA DOES NOT ASSUME RESPONSIBILITY FOR THE 4 RUNNERS. MY QUESTION IS "HOW DO I FIND OUT IF THE 2002 FRAMES WERE MANUFACTURED WITH THE SAME MATERIALS THAT THE 2003 MODELS WERE MADE OF?" I REALLY WANTED TO HAND THIS CAR DOWN TO MY DAUGHTER. SHE NEEDS A CAR AND WITH THE CURRENT SITUATION OF THE FRAME, THERE IS NO WAY I CAN LET HER DRIVE THIS IN ITS CURRENT CONDITION. PLEASE HELP!!!
NHTSA ODI #11132934
Mileage unknown · Sep 27, 2018
Structure
CHECK ENGINE LIGHT COMES ON SO I TAKE MY 2002 4 RUNNER TO GET IT CHECKED. I NOTICED IT SOUNDS LIKE IT MIGHT BE A EXHAUST PROBLEM. THEN I GET THE BAD NEWS . THE FRAME EXPERIENCE EXCESSIVE CORROSION. MY UNDERSTANDING IS THAT THERE WAS SOME KIND OF RECALL ON THIS MATTER A FEW YEARS AGO BUT I NEVER RECEIVED A NOTICE .I PURCHASED IT…
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CHECK ENGINE LIGHT COMES ON SO I TAKE MY 2002 4 RUNNER TO GET IT CHECKED. I NOTICED IT SOUNDS LIKE IT MIGHT BE A EXHAUST PROBLEM. THEN I GET THE BAD NEWS . THE FRAME EXPERIENCE EXCESSIVE CORROSION. MY UNDERSTANDING IS THAT THERE WAS SOME KIND OF RECALL ON THIS MATTER A FEW YEARS AGO BUT I NEVER RECEIVED A NOTICE .I PURCHASED IT USED IN 2003 SO MAYBE THE NOTICE WENT TO THE FIRST OWNER. I HAVE BEEN LIVING AT THE SAME ADDRESS SINCE I OWNED IT.
NHTSA ODI #11131860
Mileage unknown · Sep 17, 2018
StructureSuspension
REAR AXEL IS RUSTED OFF THE FRAME, AND ROTTING, MECHANIC SAYS IT'S UNSAFE TO DRIVE
NHTSA ODI #11130001
91,000 miles · Sep 17, 2018
Structure
LEAVING WORK FRIDAY OF LABOR DAY WEEKEND 2018 I NOTICED THE SMELL OF GAS. MY CO-WORKER ALSO LOOKED, AND OBSERVED A PUDDLE OF GASOLINE UNDER THE CAR. SINCE THE DEALER WAS CLOSE, I TOOK THE RISK TO DRIVE IT THE DEALER. THE DEALER IS HERITAGE TOYOTA IN BALTIMORE MARYLAND. THE CAR HAS ONLY 91000 MILES ON IT. THE ENTIRE BOTTOM OF…
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LEAVING WORK FRIDAY OF LABOR DAY WEEKEND 2018 I NOTICED THE SMELL OF GAS. MY CO-WORKER ALSO LOOKED, AND OBSERVED A PUDDLE OF GASOLINE UNDER THE CAR. SINCE THE DEALER WAS CLOSE, I TOOK THE RISK TO DRIVE IT THE DEALER. THE DEALER IS HERITAGE TOYOTA IN BALTIMORE MARYLAND. THE CAR HAS ONLY 91000 MILES ON IT. THE ENTIRE BOTTOM OF THE CAR IS RUSTED OUT. THIS IS WHAT CAUSED THE FUEL LEAK. THE FRAME IS ALSO RUSTED OUT TO THE POINT OF NOT BEING SAFE ANYMORE. MY COMPLAINTS ARE THESE: 1. THE UNDERSIDE OF THE CAR COMPLETELY RUSTED OUT. 2. OTHER TOYOTA TRUCKS OF THE SAME YEAR ARE HAVING THEIR FRAMES REPLACED BY TOYOTA. 3. MY TOYOTA WAS SERVICED WITH ME LETTING THE DEALER DO "ANYTHING IT NEEDS". I ESTIMATE SPENDING ABOUT $15,000 AT THIS DEALER. NEVER ONCE WAS I TOLD THERE WAS A RUST PROBLEM. WITH MOUNTING REPAIRED COSTS, I TOOK IT TO ANOTHER MECHANIC WHO IMMEDIATELY RECOMMENDED THAT I TAKE THE CAR TO THE DEALER FOR ASSESSMENT. NEVER DID THE TOYOTA DEALER WARN ME ABOUT THE RUST. 4. TOYOTA WAS COMPLETELY UNINTERESTED IN HELPING. I DID FILE A COMPLAINT #1808271490
NHTSA ODI #11129829
Mileage unknown · Sep 4, 2018
Structure
MY FRAME IS SUFFERING FROM PREMATURE AND EXCESSIVE RUSTING, AS IS COMMONLY REPORTED AMONG OTHER EARLY TO MID 2000'S 4RUNNER OWNERS. THE MOST SEVERE AREA IS THE RADIATOR SUPPORTS. I AM FILING THIS COMPLAINT SO IT IS REGISTERED AMONG THE MANY COMPLAINTS RECEIVED ABOUT THIS ISSUE. I'D BE HAPPY TO PROVIDE DOCUMENTATION IF NEEDE…
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MY FRAME IS SUFFERING FROM PREMATURE AND EXCESSIVE RUSTING, AS IS COMMONLY REPORTED AMONG OTHER EARLY TO MID 2000'S 4RUNNER OWNERS. THE MOST SEVERE AREA IS THE RADIATOR SUPPORTS. I AM FILING THIS COMPLAINT SO IT IS REGISTERED AMONG THE MANY COMPLAINTS RECEIVED ABOUT THIS ISSUE. I'D BE HAPPY TO PROVIDE DOCUMENTATION IF NEEDED, BUT I'M PRETTY SURE THERE HAVE ALREADY BEEN A LOT OF REPORTS OF THIS SINCE THERE'S NOW AN INVESTIGATION INTO THE ISSUE.
NHTSA ODI #11124282
216,878 miles · Aug 23, 2018
StructureSuspension
FRAME RUST ON THE INSIDE PORTION FOR THE FRAME. 33" HOLE RUSTED THROUGH COMPLETELY ON PASSENGER SIDE. RUST CONTINUES ABOUT 80% OF THE WAY THROUGH THE REAR LOWER CONTROL ARM MOUNT. DRIVER'S SIDE HAS A SIMILAR AMOUNT OF SEVERE RUST THAT HAS WEAKENED THE STRUCTURAL INTEGRITY OF THE FRAME TO THE POINT WHERE IT IS NO LONGER SAFE TO D…
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FRAME RUST ON THE INSIDE PORTION FOR THE FRAME. 33" HOLE RUSTED THROUGH COMPLETELY ON PASSENGER SIDE. RUST CONTINUES ABOUT 80% OF THE WAY THROUGH THE REAR LOWER CONTROL ARM MOUNT. DRIVER'S SIDE HAS A SIMILAR AMOUNT OF SEVERE RUST THAT HAS WEAKENED THE STRUCTURAL INTEGRITY OF THE FRAME TO THE POINT WHERE IT IS NO LONGER SAFE TO DRIVE. SHOULD THE CO TROLL ARM MOUNT FINISH RUSTING THROUGH, THE AXLE WILL NO LONGER BE ATTACHED TO THE FRAME ON THAT SIDE. THERE IS NOTICBLE FLEX AND SOUND ASSOCIATED WITH THE FRAME ROT. IT IS ONLY A MATTER OF TIME BEFORE THE CONTROL ARM MOUNT DISCONNECTS COMPLETELY, OR THE FRAME BUCKLES.
NHTSA ODI #11121804
Mileage unknown · Aug 21, 2018
Structure
RUSTED THROUGH FRAME ON THE REAR PASSENGER SIDE WHERE AXLE SUPPORT CONNECTS TO FRAME. MEASURES APPROX 2.5 FEET. REAR END FEELS LOOSE WHEN NAVIGATING TURNS.
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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