Structure. Review the 309 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
Suspension. Review the 108 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
Service Brakes. Review the 57 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →

NHTSA owner reports · September 18, 2026 snapshot.

23 crash reports3 fire reports14 injury reports

Structure complaints

309 reports

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Mileage unknown · Jul 28, 2021

Structure

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My Frame is a rusted mess. The entire frame is experiencing rust issues. My rear sway bar rusted off and broke into pieces (1/15/21). Now my exhaust pipe has fell off the muffler due to rust (7/21/21). My brake calipers have been very badly rusted as well as the pieces that hold my shocks and suspension in place. It has been progressively getting worse over the past 3-4 years. I feel like this has now become a safety issue and I'm not sure if it's safe to drive. It may be a risk to myself and other drivers on the road. My mechanic has told me that it will not improve and he thinks that the frame and other parts should be recalled. I have plenty of photos if needed. Please help me before something goes wrong.

NHTSA ODI #11426842

Mileage unknown · Jul 19, 2021

StructureUnknown Or Other

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My 2004 Toyota 4Runner has holes multiple inches in diameter rusted completely through the frame in multiple locations including where frame rails meet and are welded. This 4Runner is very clean and well kept in a climate controlled garage. The 4Runner was somehow not captured in the class-action law suit against Toyota that included the Tacoma, Tundra and Sequoia. Toyota has long known the frames are prone to excessive, premature rust corrosion because the frames were not properly prepared and treated against rust corrosion when they were manufactured and yet it has failed to offer significant help to owners. The excessive rust damage on my Toyota 4Runner compromises the vehicles safety, stability and crash worthiness because important suspension components, engine mounts, transmission mounts and body mounts anchor to the vehicles frames. I have spoke with a local Toyota dealer who stated they would inspect the vehicle with a diagnostic fee of $139 but that Toyota would not help with repair or replacement of the frame. There is no need to inspect the vehicle as I have multiple pictures illustrating the magnitude of the rust damage to the frame including several holes multiple inches in diameter in critical locations of the frame. I have attached several photos of the rust damage as well as photos of the body for reference to how well kept the vehicle is.

NHTSA ODI #11425484

Mileage unknown · Jul 12, 2021

StructureUnknown Or Other

Last year the frame showed rust and holes and was rejected by the inspector. We were able to get the worst hole patched and it passed inspection. I am afraid the car might be unsafe.

NHTSA ODI #11424365

130,000 miles · Jul 1, 2021

Structure

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The contact owns a 2004 Toyota 4Runner. The contact stated while driving at various speeds, there was a loud sound coming from underneath the vehicle. The contact looked under the vehicle and saw several holes throughout the subframe of the vehicle due to rust. The vehicle was taken to an independent mechanic where it was diagnosed with the subframe needing to be replaced. The vehicle was not repaired. The manufacturer was informed of the failure and informed the contact that the Vin was not under recall. The failure mileage was approximately 130,000.

NHTSA ODI #11423163

Mileage unknown · Jun 25, 2021

Structure

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On April 14, 2019, I was informed by an auto repair shop that my 2004 Toyota 4Runner showed signs of excessive rusting on the front end of the frame at the bumper and radiator support. The repair shop owner/mechanic indicated the bumper may eventually fall off. At the time, the odometer reading was only 117,834 miles. On June 22, 2021, I took the truck in to the Toyota dealer where I purchased it to have the regular oil change done and requested that they inspect the frame during the routine "Multi-Point Inspection." On this visit to the Toyota dealer, the truck's odometer reading was 141,595. The mechanic pointed out the more severe areas of rusting, which included the "Front right bumper support crumple zone area, also right side top under pass front seat area very thin." He indicated that the left side of the frame, although not as advanced as the right side, was also rusting, because water from wet roadways accumulates within the frame and does not drain. I was not able to take photos of the top under pass due to lack of access. However, the mechanic had me run my fingers along the top of the frame. The frame was so corroded that it was crumbling, and my fingers went right through the frame. Some areas already had holes from the corrosion. I have included both the repair shop and Toyota dealer's observation reports as well as the photos of the front end of the frame and the right side under pass. It was not possible to take photos of the top of the right side under pass, which the mechanic pointed out was the most affected. The vehicle is available for inspection if necessary.

NHTSA ODI #11422372

Mileage unknown · Jun 21, 2021

Structure

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On April 17, 2019, I was informed by P.R. Auto Repair that my 2004 Toyota 4Runner showed signs of excessive rusting on the front end of the frame at the bumper support and radiator support. This observation was noted by the auto repair shop's owner. It is important to point out that my truck had only 117,834 miles on its odometer and should not already have had such a serious rusting problem. My truck was in for replacement of rear pads and rotors and was on a lift when the problem was noted. At the time the problem was being pointed out to me, a portion of the rusted metal in that area came right off. I was told that eventually the bumper could fall off and potentially lead to increased more dangerous problems. I have taken my 4Runner to A-1 Toyota where I purchased the vehicle for the regularly scheduled oil changes. "A-1 Toyota Quality Vehicle Inspections" were conducted each time with issues that required further attention noted in the report, but the rusting problem has never been included in the reports or pointed out to me. The truck now has just over 141,240 miles on its odometer and the corrosion problem has become significantly worse and my safety and the safety of others has become a growing concern to me. I have included a scanned copy of the April 19, 2019 invoice/receipt from the P.R. Auto Repair shop. The observation of the problem is noted under the Instructions section. I have also included two photos (one of the left side view and one of the right side view). The vehicle is available for inspection upon request. I understand that there is currently an ongoing investigation related to excessive rusting on Toyota 4Runners' frames. It is my hope that my 2004 Toyota 4Runner can be recalled for this problem as were other makes of Toyota vehicles that suffered the same problem before mishaps or tragedies occur as a result.

NHTSA ODI #11421728

Mileage unknown · Jun 8, 2021

Structure

Severe rusting of body frame

NHTSA ODI #11420142

Mileage unknown · May 20, 2021

Structure

The frame is rusted very badly and may need to be salvaged. Many of the other Toyota vehicles in this same year which have the same frame have already been recalled. Why not the 4runners? I've owned many other early 2000's vehicles and none have had this bad of rust. Simple not acceptable and not safe!

NHTSA ODI #11417947

143,000 miles · May 4, 2021

Service BrakesStructureSuspension

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OUR 2004 TOYOTA FORERUNNER WITH V6 ENGINE WAS PURCHASED AS A USED VEHICLE IN 2019 WITH 106,000 MILES ON IT. SINCE THEN, IT HAS DEVELOPED MORE AND MORE AREAS OF RUST ON THE FRAME DESPITE OUR EFFORTS TO MITIGATE THIS ISSUE. WE HAVE HAD TO REPAIR THE FRAME, SUSPENSION, BRAKES, AND WHEEL BEARINGS. WE CONTINUOUSLY INSPECT THE UNDERCARRIAGE AND CONTINUE TO DISCOVER MORE AND MORE AREAS OF SIGNIFICANT RUST/DETERIORATION DESPITE EFFORTS TO CLEAN, TREAT (WITH PAINT, RUST INHIBITORS, WELDING REPAIRS). WE ARE CONCERNED THAT THIS DETERIORATION WILL SOON RESULT IN A CATASTROPHIC FAILURE AND POSSIBLE ACCIDENT RESULTING IN PROPERTY DAMAGE, INJURY, OR DEATH.

NHTSA ODI #11415201

Mileage unknown · Apr 29, 2021

Structure

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THE ORIGINAL FRAME ON OUR CAR IS ALMOST COMPLETELY RUSTED. THERE ARE HOLES IN THE FRAME AND COMPLETE CORROSION ALONG THE SIDE BEAMS. THIS IS A HUGE SAFETY HAZARD WHILE DRIVING. THERE IS SO MUCH RUST ON THE UNDERBODY. ALL PARTS ARE COMPLETELY STOCK AND ORIGINAL. THIS SHOULD NOT BE A PROCESS WE HAVE TO PAY FOR AS IT IS A MAJOR SAFETY CONCERN THAT TOYOTA IS COMPLETELY OVERLOOKING. THE HOLES IN THE FRAME ARE ABOUT A BASEBALL SIZE WHOLE. I HAVE TAKEN IT TO OVER THREE MECHANICS AND A BODY SHOP RECOMMENDED FROM TOYOTA AND EACH OF THEM SAID THE FRAME IS ALMOST ENTIRELY UNSAFE.

NHTSA ODI #11414522

Official recalls

16V065000 · Air Bags:side/window

Feb 5, 2016

Toyota Motor Engineering & Manufacturing (Toyota) is recalling certain model year 2003-2006 Toyota Land Cruiser and Lexus LX470, 2005-2006 Toyota Tundra and Sequoia, 2004-2006 Toyota 4Runner and Lexus GX470 vehicles equipped with side curtain-shield-air bags. The affected vehicles have an air bag control module that may be improperly programmed, causing the side curtain-shield-air bags to deploy inadvertently.

Consequence & remedy

Consequence: If the side curtain-shield-air bags deploy unexpectedly, it can increase the risk of occupant injury.

Remedy: Toyota will notify owners, and dealers will replace the air bag control module with one that has improved programming, free of charge. The recall began on December 1, 2016. Owners may contact Toyota customer service at 1-888-271-9371. Toyota's number for this recall is G0C and GLB.

11V113000 · Vehicle Speed Control:accelerator Pedal

Feb 24, 2011

TOYOTA IS RECALLING CERTAIN MODEL YEAR 2008 THROUGH 2011 LEXUS LX570, 2003 THROUGH 2009 TOYOTA 4RUNNER, AND 2006 THROUGH 2010 RAV4 VEHICLES. THE ACCELERATOR PEDAL CAN GET STUCK IN THE WIDE OPEN POSITION DUE TO ITS BEING TRAPPED BY AN UNSECURED OR INCOMPATIBLE DRIVER'S FLOOR MAT.

Consequence & remedy

Consequence: A STUCK OPEN ACCELERATOR PEDAL MAY RESULT IN VERY HIGH VEHICLE SPEEDS AND MAKE IT DIFFICULT TO STOP THE VEHICLE, WHICH COULD CAUSE A CRASH, SERIOUS INJURY OR DEATH.

Remedy: THE REMEDY IS NOW AVAILABLE. THE SAFETY RECALL BEGAN EARLY APRIL 2011. THE REMEDY WILL INVOLVE MODIFICATION OR REPLACEMENT OF THE ACCELERATOR PEDAL AND REPLACEMENT OF ANY TOYOTA ALL-WEATHER FLOOR MAT. OWNERS MAY CONTACT TOYOTA AT 1-800-331-4331 OR LEXUS AT 1-800-255-3987.

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

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

RQ10003 · Unintended And Uncontrolled Acceleration

Opened Feb 16, 2010 · Closed Mar 1, 2011

Status: closed (inferred from source dates) · Electrical System:software; Vehicle Speed Control:accelerator Pedal

On February 16, 2010, NHTSA's Office of Defects Investigation (ODI) opened RQ10-003 to determine whether the scope of prior Toyota recalls relating to potential unintended acceleration were sufficiently broad, including, among others, Toyota recalls 07E-082, 09V-388, 10V-017, and 10V-023.NHTSA also requested information regarding potential electronic causes of unintended acceleration in Toyota and Lexus vehicles.I. Pedal Interference from Floor mats, Carpet Covers and Plastic Pads in Carpets.During the RQ10-003 investigation, ODI reviewed a large volume of documents to assess whether additional vehicles should be recalled.Following the agency's analysis, NHTSA requested that Toyota recall additional vehicles.Toyota complied with the agency's request.The details of these recalls are set forth more fully in Toyota's reports to NHTSA pursuant to 49 CFR Part 573.These recalls are as follows:Recall 11V-112: (1) model year (MY) 2004-2006 Toyota Highlander and Highlander Hybrid; and, (2) MY 2004-2007 Lexus RX330,RX350, and RX400h (hybrid model). The total estimated population under this recall is 769,379 vehicles.This recall remedies potential accelerator pedal entrapment caused by a loose floor carpet cover (trim panel). Recall 11V-113: (1) MY 2003-2009 through 2009 Toyota 4Runner; (2) MY 2006-2010 Toyota RAV4; and, (3) MY 2008-2011 Lexus LX570.The total estimated population under this recall is 1,381,000 vehicles.This recall supplements recall 09V-388 and remedies potential accelerator pedal entrapment by an unsecured floor mat.Recall 11V-115: (1) MY 2006-2007 Lexus GS300 (all wheel drive vehicles); and, (2) MY 2006-2007 Lexus GS350 (all wheel drive vehicles). The total estimated population under this recall is 19,647 vehicles.This recall remedies potential accelerator pedal entrapment caused by inadequate clearance between the pedal linkage and a plastic pad embedded in the vehicle's carpet.II. Potential Electronic Causes of Unintended Acceleration.After NHTSA opened RQ10-003, NHTSA launched a ten-month study of potential electronic causes of unintended acceleration in Toyota vehicles.NHTSA launched the study in the spring of 2010 in light of concerns aired in Congressional hearings.NHTSA enlisted engineers at the National Aeronautics and Space Administration (NASA) with expertise in areas such as computer controlled electronic systems, electromagnetic interference and software integrity to assess whether electronic systems or electromagnetic interference played a role in incidents of unintended acceleration in Toyota vehicles.That study has concluded.Two reports are associated with the study and are available on NHTSA's website.NASA's report is entitled Technical Support to the National Highway Traffic Safety Administration (NHTSA) on the Reported Toyota Motor Corporation (TMC) Unintended Acceleration (UA) Investigation, NESC Assessment No. TI-10-00618 (Jan. 18, 2011).NHTSA's report is entitled Technical Assessment of Toyota Electronic Throttle Control (ETC) Systems (Feb. 2011).Both reports should be read in conjunction with each other. As stated in its report, NASA did not find an electronic cause of large throttle openings that can result in unintended acceleration incidents. NHTSA did not find a vehicle-based cause of unintended acceleration incidents other than the physical pedal interference causes that are being addressed by Toyota's recalls. This RQ is closed.

Additional source detail variants (6)

Electrical System:software

Vehicle Speed Control:accelerator Pedal