Problems with 2002 Toyota 4Runner STRUCTURE

I purchased the 2002 4runner in 2014. at that time, the 4runner only had 79,000 miles and had been cared for meticulously. i have taken the car in for routine service over the past 5 years. upon taking the 4runner in due to a vibration and check of the differential, the mechanic called me in to look at the frame while it was up on the lift. below in the attached photos, there is extensive rusting of the rear differential, axle and frame. the vehicle was stationary and the issue was found during routine maintenance. the rusted frame and differential have rendered this vehicle practically valueless and unsafe.

Very excessive rusting and corrosion on the frame near where the leading arm attaches on the passenger side. hole has developed very quickly, only in the span of a couple years. when going around left corner >15mph, a clunking noise can be heard from the problem area. very occasionally a similar noise can be heard when going through right turns. vehicle has spent most of its life in southern minnesota, although some time has been spent in south florida. repair will be necessary soon, as i'm starting to not feel safe driving long distances or at highway speeds (70+ mph). thank you, have a nice day. *tr

Right frame rail is very rusted to the point of non repair. unable to repair suspension due to unable to remove bolts that hold suspension to frame.

Vehicle frame has corroded, fractured especially on passenger rear of vehicle. many holes along frame. was hearing loud thunking in rear of vehicle took it in for a visual inspection and found the issue.

I was doing an oil change and noticed that the frame was rusted very badly . i think that there should be a recall on this model 3rd gen 4runner (1999-2002)this is the same frame as the truck that was recalled ,so this should be included .if this frame breaks it will hurt or kill some one .

We purchased a 4runner for our 18 year old daughter to drive thinking it would be safe, esp in mn. she was driving home from college (130 miles) and noticed it had a bad vibration, especially over 40 mph. it was very difficult to drive. we were out of town and when we got back, brought it to the shop, only to be told the frame was responded beyond repair (see photos). not only does that scare me for my daughter, but she has been driving it a few years and had friends and other family members in the vehicle. the vehicle has relatively low miles for it's age and based on toyotas reputation of longevity, we never expected this sort of issue. we're thankful she wasn't hurt, but are concerned about others driving a vehicle and not knowing it could literally break in half while driving down the road!

I have seen classi. cars from the 60s with frames in better shape than my 4runner. the rear control arms brackets are close to detaching from the frame. rust is eating the back half of my frame. the frame rails are completely rusted through and will soon need replacing. there are numerous bolts and hardware that can no longer be used due to rust. the fill plug on the rear differential has rusted away as well. the quality of this steel is absolutely horrible. toyota should be ashamed of a vehicle that has problems like this. i have never seen rust this bad on a frame before.

First, the motor blew for no reason at 152,000 miles. i rebuilt the car and had a new motor put in. i was not aware of the rusting frame issue, however, after driving the vehicle with a lovely new rebuilt motor for about one year, the frame rotted beyond repair causing the power steering to go out. i don't drive much, so there was no excessive exposure to salt. the car was parked in my driveway. it was an exceptionally cold day. i started the vehicle and found the power steering fluid had frozen and lost all the fluid as a result of the steering rack being rusted and weakened. the repair shop told me that the frame and rocker panels are severely compromised too badly to bother fixing the steering rack. the car is not safe to drive.

At a stop light, went to drive heard load pop clank. vehicle started shaking and driving funny. looked under car and my control arm ( that stabilizes my axel ) mount rusted off. my entire under carriage is rusted out. the control arm shifted

Excessive rust on frame. rusting from the inside out, on passenger side near muffler, by rear suspension mounts. rusted all the way through on the inside of the frame. likely rusted in other parts that are not visible.

My 2002 toyota 4runner has excessive rust on the frame to the point that it has been deemed by my local toyota dealership as "unsafe to drive." it only has 180,000 miles on it, the rust should not be this extensive.

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.

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

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.

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!!!

Rear axel is rusted off the frame, and rotting, mechanic says it's unsafe to drive

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.

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

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.

Frame is completly rusted out.

Frame deterioration.

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.

Takata recall frame rusted out from the inside out. looking at on frame it was at least 1.5 inches of dirt and small rock from maine roads and than when rained it was just mud the bad spot is on the passenger side d by torsion bar no way to drain. also rear end differential gear cover rusted out on other vehicles you replaced just the cover on the 4runner i was told to replace the rear end price just for the rear end was $2500 than labor.

The frame on my 4runner is completely rusting. had to get it spot welded to pass inspection. this is a common problem on 3rd generation 4runners. please help.

I have owned my 2002 4runner since i bought it new in 2002. around 8,500 miles a year, and somehow my frame is completely rusted out. this is not normal, and now it won't pass inspection and is unsafe to drive. toyota bought the frames from a third party in japan which did not coat these frames properly. we undercoated the car for 5 years after buying it, and yet rust started showing up around 2009. we have taken care of the car, everything except the frame is perfect and clean. toyota is knowingly letting 3rd generation 4runners drivers drive their cars even when they're unsafe. they need to institute a buyback or frame replacement program. we don't know what to do now, because we can't drive or sell the vehicle, yet everything runs perfectly.

Tl* the contact owns a 2002 toyota 4runner. the contact noticed that the main frame was rusting on the vehicle. the vehicle was taken to an independent mechanic, but was not repaired. the dealer was not contacted about the failure. the manufacturer was not notified of the failure. the approximate failure mileage was 209,000.

When taken to the local automotive shop they found the frame has rotted out in many parts of the frame. cab frame mounts are also rotted. it will not pass inspection. the frame is ready to snap offf. thank the lord the shop found this being three of my four kids ride in it everyday to school.

Tl* the contact owns a 2002 toyota 4runner. while the vehicle was being serviced, the technician found severe corrosion on the passenger side. the contact stated that the frame would need to be replaced. the vehicle was not repaired. the manufacturer was not notified. the failure mileage was approximately 150,000.

Frame is perforated by rust where the rear control arm mount meets the frame rail.

Frame rust. the dealership determined the "frame is rotted-safety issue-will not pass inspection". this 4runner has only been exposed to areas of mild south east pennsylvania winters and the undercarriage was washed regularly after every snow and road-salting event. 4runner is trash after only 12 winters. 4runner was in storage for 04/05 winter and there was no snow in 15/16.

My 2002 4runner's frame is rusted through in many places. this is very unsafe and toyota should fix this problem. they have yet to recall the 4runners but, have recalled the tacoma and sequoia. i do not have the money to do this repair. i am buried in debt from a heart transplant and this is just unacceptable. i think people will die from this problem. please respond so i have some information please. thanks, [xxx] columbus, ohio information redacted pursuant to the freedom of information act (foia), 5 u.s.c. 552(b)(6). *tr

Frame is badly rusted out. vehicle only has 80,000 miles

The frame of this 4runner has been experiencing excessive rust since the time i got it used from a dealer. once their undercoating wore off, my mechanic replaced rusted up brake lines back about 9 years ago. he said it was because the frame was very rusty and they did a new rust treatment. for the past few years i have been battling issues related to the frame. a plate was put in to strengthen an area. it only has 164k on it, i rebuilt the transmission at 125k, and the body is in good shape. just that the rust is spreading everywhere underneath. we tried to get it addressed in the previous toyota frame recall but it was not for this age for whatever reason. every repair has been more difficult due to rusting bolts, mufflers rusting early, brake lines busting due to rust, the tow hitch rusted through. now there is a gaping hole in the rear side of the frame supporting the cab. after being under the car trying to scrape rust off, and to put some rust restore/protection, i saw the new hole and got fed up. so i see you are now investigating this year 4runner to add to their recall. please...do! something serious could happen while driving it and it will just stay mostly parked until this is resolved. brake failure when my son was driving was already scary enough. thank you.

My 2002 toyota 4runner has a couple quarter sized rust hole on the rear right side of the frame. located on the inside next to the exhaust muffler. the entire rest of the frame is in very good condition, it's weird to me that just this particular spot is completely rusted through, this is a huge safety hazard and i know toyota should step up and do something about this. i read online most people have this same problem in the same exact spot. seems like a defect in the frame. i'm hoping to have toyota cover this incident. thanks for reading. brandon

Tl* the contact owns a 2002 toyota 4runner. the contact took the vehicle to an independent mechanic for routine maintenance. the technician observed that the frame of the vehicle was rusted out and could not be repaired. a local dealer was not contacted. the manufacturer was not made aware of the failure. the failure mileage was unknown.

The frame of the vehicle is rotting out with rust. the 4runner has never been in snow and has been taken well care of and the frame is still eroding away with rust at an unnatural rate. this issue must be addressed for the sake of so many unaware owners!

Frame cracked/rusted dealership reported that the frame (right rear) was cracked.... car is unsafe to drive.

I visited a toyota dealership for routine maintenance (oil change) and inspection of 4 wheel drive system. after the vehicle was raised on the lift, the service advisor asked me to join him and the shop mechanic in the service bay where i was shown that the frame / chassis of the vehicle has rusted the point where in their opinion it was no longer safe to operate. after close inspection, i had agreed with their assessment. an online search for a recall notice was performed, but none was found. otherwise, this vehicle is in meticulous condition with no body damage or rust or any mechanical problems.

Frame is rusted through on right side from middle of the frame to just over the rear axel. there are large holes and rusted slots that are over 10 inches long damage starts before the rear suspenshion support and continues to the other side and the side where the rust has caused holes and long slots the whole frame can be squeezed easily with your hand.

Vehicle has 188,400 miles, runs flawlessly. bought 2005, 45k miles,toyota dealer certified used suv. rotted thru rear transfer case 3 yrs ago, replaced from a wreck. severe progressive entire frame rust/rot noted in yearly pa inspections, now cant pass inspection & pillars almost rotted thru..unsafe to drive. extremely disappointed cant pull trailer sailboat & m'cycles, now sits in driveway useless.

Vehicle was stationary. while replacing exhaust system components. found what appeared to be minor rust on the passenger (right) side rear suspension mount. further investigation uncovered a larger area of rust along the 3 welds on the inner frame rail. cut / ground the metal back to good metal and am in the process of patching for my yearly maine vehicle inspection. either toyota has built an inferior frame or the newer chemicals being used to keep the roads clear in the winter to be the cause of this rust which could cause the rear suspension to fail at this point in the frame and cause a accident.

Hello. i purchased a 2002 toyota 4runner limited edition last fall in pennsylvania. the car had passed the pennsylvania state inspection with passed validated inspection tags in the front window. i took the car to my mechanic, welder and beechmont toyota (cincinnati oh) and the consensus is the car needs the car frame replaced. the car frame has rust holes and is rusted along with a rusted undercarriage. the integrity of the car is compromised, because the car frame has rusted holes in it, criteria that should not have passed pa state inspection. it does not have a safe car frame. i was sold a vehicle that passed pa state inspection and the car had holes in the rusted car frame.the sales guy who sold me the car, said that the car had passed state inspection in which the sticker in the windshield shows. i researched the state inspection criteria and i think it is 5a and 5iii that reference checking the car frame. pendot did not take any responsibility for their failure of approving the state inspection. i asked for my money back ($6,200) from the car salesman plus i had to pay about $500 ohio tax and was told that it had passed pennsylvania state inspection and they would not refund my money. this car has a rusted damaged frame with holes and needs to be off the road as it's dangerous. i am asking for my money back, and i'll return the vehicle as it should not have passed pennsylvania state inspection. thank you. *tr

Frame rusted under 4 runner and on bumper told by person working on sway bar links. stated excessive rust on frame and rear axle.

Tl* the contact owns a 2002 toyota 4runner. the contact stated that the rear trailing arm on the vehicle prematurely deteriorated and fractured. the vehicle was towed to the contact's residence and then towed to an independent mechanic. who diagnosed that the rear end housing and axle differential needed to be replaced. the vehicle was not repaired. the manufacturer was notified of the failure. the approximate failure mileage was 64,000. updated 11/20/15*lj the consumer stated the vehicle should not have to be repaired at the owner's expense. the rear differential had to be replaced. the frame of the was also badly rusted. updated 2.3.16 *js *cn

Frame has excessive rust and has holes in parts of it. the rest of the body and interior are in great condition. engine runs well and there are otherwise no major mechanical issues. upon having a minor repair done, inspection showed that the vehicle was unsafe to drive with the frame in that condition as it is about to crack in half. this seems to be prematurely failing compared to the rest of the vehicle.

Tl* the contact owns a 2002 toyota 4runner. the contact inspected the vehicle and discovered that the entire rear end of the frame completely rusted. in addition, the rack and pinion was faulty and replaced by an independent mechanic. the manufacturer was notified of the failure. the approximate failrue mileage was 120,000.

The frame is rusting almost in two. looks like it could break any time. rear axel is also very rusted with pieces falling off. *tr

Fame deteriorating prematurely,skid plate that protects fuel tank showed signs of rust. after inspecting found rotting from inside out.when replacing in may of 2014,found that strap that holds fuel tank rusted completely away,two bolts from the rusted skid plate only thing holding fuel tank in place.same conditions exist over entire frame,rust falls off in sheets when frame is tapped on with hammer.brought my concerns to dealership in jan.of 2015 of rust issue, they informed me nothing would be done.

I was having service work done at toyota on my 2002 toyota 4runner and the service manager brought to my attention the vehicle's frame was rusting through, near the muffler and the frame would eventually fail. he said was a known defect but no recall had been issued. he also stated that the toyota tacoma had the same problem and a recall had been issued for the tacoma. the rust holes in the frame pose a serious safety issue. the service manager said he had seen other 4runners with the same issue and even suggested to those owners that their vehicle was not safe to drive. *js

Frame and rear differential rusting out. *tr