Problems with 2004 Toyota 4Runner SUSPENSION

Severe rust on frame and suspension attachment points. rust is not superficial but rusting from inside of frame tubes.

I own a 2004 toyota 4runner with significant rust on the frame that has nearly rusted through in some areas. through my research i determined that this has been an ongoing issue for many toyota vehicles close to the 2004 model year. apparently the frame was not properly coated and rust has grown on my vehicle as well as many others at a much faster rate than is typically expected. i am worried about the safety of my vehicle as a result.

Takata recall, the radiator mount and frame supports are rusted out, also the rear shock and air suspension mounts are rusted out. vehicle was in motion when shock mount broke.

'frame rust' frame rusted in 2 areas and mechanic deemed unsafe to drive.

Frame rust in 2 areas; mechanic deemed unsafe to drive

The frame on my 2004 toyota is very rusty. it is completely cracked through near the front passenger suspension. my mechanic has warned me not to drive the vehicle anymore. see pics

Excessive frame rust. replaced complete rear end in 2013. told by hyannis toyota that it was unsafe to drive because of excessive rust. the rear end is now rusted out again in 2019 and needs replacing. in april 2019 could not have suspension replaced until frame welding was completed. additional work of cutting out rear upper trailing arm brackets and weld in place and fabricate fuel tank strap mount and weld in place. complete frame and underside of this vehicle is completely rusted out. we had this work down because the gas tank was falling out and we could not drive this vehicle.

Frame and suspension rust has weakened the parts to the point of failure. rear upper control arm mounting bracket on rear axle broke while driving on highway while going around a turn. vehicle's rear wobbled back and forth violently. i almost lost control of the vehicle. there are other pieces that look close to failure.

The frame of my truck is complete mush! i've taken excellent care of my 4runner as it has been my most favorite vehicle. i'm being warned to get this fixed due to it being a dangerous situation & wouldn't you know i'm driving home & i loose all control over my vehicle on hellacious mountain roads, brakes completely gone! everything rotten! why weren't we notified how dangerous these trucks truly have become?

Excessive frame rot/rust

Was driving to work going 50 mph braked to come to a stop and the back end started to turn almost had an accident. frame is completely rusted out. too dangerous to drive.

Rust crack in frame right front at core support. cracks in dashboard.

I just took the car for annual state safety inspection. it failed and the inspector said it is unsafe to drive. the part of the frame that connects the right front and right rear suspension is so rusted that the car is unsafe to drive. we have been driving this vehicle with no knowledge of this hazard.

Rear frame rusted through. i was driving and a piece holding the suspension together rusted off the frame. the vehicle was in motion and it felt like it was going to tip over. it also felt like the front and back wheels were going in different directions. apparently a very common issue.

Excessive rust is compromising steering control.

I took vehicle in for brake repair, the mechanic noted excessive frame rust and cautioned that it may be unsafe to continue to operate the vehicle with out remedy. recommended thousands of dollars worth of repair work. i am the second owner of the 4runner, but the suv spent most of its life in arizona, away from harsh winters and salted roads. loyal toyota customer, but very disappointing because i planned to keep this suv until it was vintage, but now i am afraid to drive it or sell it to someone else.

My 16 year old daughter was driving on a city street and was turning into a driveway and the lower control arm on passenger side broke and i was told it was because the frame is rotted. not sure if i am able to fix due to the frame. i am new to the northeast and was not aware of rotted frames out here.

Transmission failed due to rusted transmission lines. leads up to finding out that frame is completely rusted out. unable to fix it due to frame rust. suspension are of frame rusted as well...barely holding on. traveling from tn to pa when all this happened.

Frame is extremely rusted, it just flakes off and after inspecting the joints am afraid that it will soon become a safety hazard also the brake calipers become in-op (frozen) have replaced the 2 front calipers 3 times and the 2 rear calipers twice

Parts of the vehicles exterior and including frame and subframe components are excessively rusted. parts are of the suspension and other hard parts are having to be replaced due to corrosion.

Extensive rust and corrosion on frame and suspension parts. i am the original owner and the vehicle has 134,000 mile. advised by technician that this is not normal wear.

We have a 2004 toyota 4runner with 121,510 and we're informed that the whole frame is rusted. we learned that toyota had a similar issue with frames in other vehicles for the same reason and it was recalled for those vehicles but there is no recall on the 4runner. my vehicle runs well and has no issues other than the frame which we were told makes the vehicle unsafe. we've had toyota's in the past with well over 300,000 miles so this was a shock that we cannot use it anymore. we were informed the frames were outsourced and the company used did not put the proper amount of zinc on frames which caused them to rust.

Takata recall frame is completely rusted. causing all the undercarriage to rust out and make the vehicle very dangerous to drive. even the body is starting to rust away. only has 116,000 miles on it which is crazy.

My 2004 toyota 4 runner is in the dealer for routine maintenance. most of the car maintenance have been at this local toyota dealership. i just had the cv boots and sway bar bushings replaced this past spring and summer. i have the records for these particular maintenance and repair. my service mechanic mentioned there is significant amount of rust on the frame/ chassis. on september 7, the mechanic at the same dealership showed me again the excessive rust on the frame. it is so severe, one of the loops for towing the truck in the front of the frame just broke off. i attached the picture of the broken hook/loop in this document. the truck has 102,000 miles on it. it is mostly in the garage if not being used. i understand that other models in the same years like the toyota tacoma & toyota seqoiua have the same excessive rust but there is an already recall program for these models. do the 4 runner from the same years have the same frames. why is there no recall for the 4 runner for the excessive rust isssue which can be a safety problem for the driver and the passengers? the mechanic does not reccomend me driving this car due to the excessive rust. the mechanic warned me that rust is so excessive that my radiator can just fall off because the part of the frame holding it in place is so corroded from rust. i am hoping toyota can address this issue sooner than later. it is a safety issue.

Frame has rotted and has been declared unsafe to drive.

Since vehicle was 5yrs old the frame has rusted terribly. the rust is so significant there are holes and pieces of it have just fallen off. currently, the steering joint is so rusted that it cannot be driven safely because it feels like it may lose control on the road. entire undercarriage appears so badly rusted that i am not sure this vehicle is safe to drive anymore.

Toyota truck frame corrosion upon installation of failed suspension components on my 2004 toyota 4runner, my independent mechanic informed me of substantial frame corrosion. i contacted lynch toyota with my concerns, lynch toyota inspected my 4runner and found substantial frame corrosion, vehicle deemed unsafe, and should not be driven in any capacity, frame replacement recommended by lynch toyota in manchester connecticut. the steering shaft is frozen and binding due to corrosion. the suspension components are in jeopardy of breaking away from corroding frame. toyota refuses to include vehicle in frame replacement program offered to all other body on frame constructed trucks. 4runner frames are failing in the same way as tacoma, sequoia and tundra, yet toyota claims that no program is in place to assist you, sorry for your troubles was toyota's response when contacted by phone on two occasions post inspection of my 4runner by lynch toyota.

Since buying my forerunner used in 2015 i have only brought it to the dealership for maintenance bed inspections with toyota professional mechanics. upon bringing my vehicle in for a routine oil change and inspection i was told that the frame is rusted out and unsafe to drive. i was shocked and upset as i've only used a trusted toyota professional mechanics and somehow they seem to have overlooked a frame that was completely rusting out and therefore putting my life and my children's lives in harms way. i contacted toyota headquarters to no avail, they claimed there's nothing they can do as there are no recalls. however i feel they are responsible for their professional mechanics overlooking such a serious issue but yet having no problem with me continuing to put money into this vehicle as i planned on owning it for quite some time. after the frame rust was pointed out my steering then separated from the suspension while driving home being a single mother and having only one vehicle i had no choice but to try to drive it i am extremely upset and this is completely unacceptable

While driving on the highway my car went out of alignment due to a rotten torsion bar mount. the entire frame also has lots of rot

The frame and structure have rusted from the inside out to an alarming degree. specifically at the frame weld points in midsection and the rear attachments to axle. it is a safety hazard and it has rusted far more quickly and dramatically than any of the other components. none of my other vehicles have deteriorated in this way.

Premature rusting if the frame and other components of the vehicle. driving could be or turn into a safety hazard.

I've had this 2004 toyota 4runner since 2004 i bought it new and have taken good care of it. the body still looks great, no rust on body just has 94000 miles on it. but the under side is awful the frame has holes rusted through at high pressure points like suspension points, cross members for transmission and engine rusted through, its to point that its dangerous to drive. i was told by toyota service rep that the frame has a fifteen year warranty on them but together are saying they can't fix or place it and it looks like i'm not alone on this issue. toyota should step up and back their product especially in safety issues. they were forced to replace frames on the tacoma's. what's funny i've been told by toyota reps also that the 4runner has the very same frame as the tacoma's. so if that's so why can't they replace these also? i think this is really bad, you pay a lot for a vehicle and it still looks like new but have to consider parking it because you fear for your families lives. it's getting to point you can't trust it on the road. i think toyota should be held accountable.

Frame is rusting out creating a driving hazard which could result in injury to driver and or passengers

My 2004 toyota 4runner frame/chasis is rusted throughout. everything that is not plastic or rubber on the chasis is rusted out. the skid plate is rusted through in several places and needs to be removed or replaced before it falls off. toyota has recalled vehicles in the past as well as replaced chasis on all but the 2004. toyota needs to take responsibility and recall the 2004's. the body is in good shape with no rust.

The fram is excessively rusted from years in 'cold weather states.

Frame and rear axle housing rust - caused the upper control arms, which prevent rotation of the rear axel, to disconnect from the housing/frame. also, steering has become stiff and bumpy as you turn the wheel. this may be due to front crossmember rust or rust on the steering universal joint. i live on long island and have the car bottom washed whenever it has been exposed to snow melting salts/compounds. my mechanic says the car is not safe to drive.

My 2004 4runner, with less than 80,000 miles, has significant and overwhelming under carriage rust. there is a frame rot hole. one of the trailing arm brackets on the axle has rusted to the point where the trailing arm was no longer connected. this is one of the points where the axel is connected to the vehicle and keeps the axel from rotating. there are front suspension parts completely rusted to the point my vehicle can no longer receive a successful front end alignment. these are the biggest problems, there are several other issues due to unbelievable rust.

My 2004 toyota 4runner has extreme amounts of rust on the frame to the point where there are actual holes forming. this is a major structural issue for the vehicle and incredibly unsafe. i worry that this may cause an accident or render my vehicle inoperable in the future.

Well maintained vehicle failed nh state safety inspection based on significant frame rust. rust points around radiator support mounts, and passenger side rail, near muffler mount, and rear suspension mount point. with damage, car is unsafe to drive. toyota states no resolution option exists. similar year tacomas frames are being replaced with identical damage.

Looks like the fran around and in front of the front suspension is rusting in two

Rust eat my frame into

There is excessive rust/corrosion on the frame of the truck. the skid plates completely rusted off the truck in 2010. the transmission lines have corroded to the point they have to be replaced. the engine oil cooler and radiator supports have rusted through. the exhaust rusted off the truck in 2010 as well. currently there is extensive corrosion on the frame of the truck and the suspension components. these issues appeared in 2010 and i have been fighting them ever since. mechanically the truck runs great, never a problem, however the vehicle's frame is disintegrating due to corrosion.

Vehicle has 129,881 miles. severe rust through of frame underside. had plated & welded. new rust through holes appeared within 6 months of previous weld on same frame structure but in different locations posing imminent rust through failure in center of vehicle. cannot pass safety inspection.

Frame has started rusting near welds and holes. very poor prevention of rust by toyota. skid plates totally rusted out and fuzed bolts. rear diff housing is also rusty. car will probably fall apart in a year or two.

I was going 5 mph and hit my brakes. the control arm was ripped from the frame due to rot/rust. toyota is aware of this problem for 4runners, but has only offered assistance on the tacoma and tundras. the body of my vehicle has no rust anywhere, and the mileage is extremely low. i cannot even find a mechanic to fix it, because the frame is so bad. i was told, if it gets fixed, another part of the frame may fail when i'm cruising on the highway and people could get hurt or killed. no mechanic wants this liability in doing a repair.

Went in for a oil change and was offered a 28 point inspection. at dealership, ira toyota, milford, ma 28 point inspection tells us there is holes and rust in the frame and the vehicle would not pass inspection. this 4runner has been kept in mint condition with receipts to prove. did some research on line to learn many 4runners and tundra's have been recalled for just this reason. updated 7/23/15*cn *tr updated 9/20/2017*cn

There is lot of rust on frame, under carriage and its also in the suspension. its also causing fluids to leak and i had to replace the muffler assembly due to rust. i purchased this car as certified used from prestige toyota of nj with only 5000 miles in august of 2005, i purchased this toyota because of their stellar reputation in the auto industry but i am extremely disappointed with this car. i have less than 109,000 miles and at the way this rust is progressing, i will have to junk the car very soon. i cant risk being on the road with my family and have this rust bucket fall apart on the middle of the road. i have been waiting to see if there is a recall but haven't seen anything come through yet. please include my car in any vehicle safety recalls, or class action suits against toyota. thank you

Frame is rusting out. *tr

Vehicle has abnormal amount of rust on frame metal parts with excessive chipping an corrosion. also, of almost more concern is that the airbag sensors are completely rotted through, as if they were sacrificial anodes. frame failure due to abnormal rust could cause a catastrophic accident. sensor failure of the airbag sensors (behind front bumper) while driving could cause serious injury or death to driver or other cars on the road. i have never seen anything like this amount of corrosion. *tr

2004 4runner limited, frame rusted out. *tr