Problems with 2004 Toyota 4Runner STRUCTURE

Excess rust on frame. it was concluded by repair shop not able to pass inspection due to safety.

Frame rust - vehicle failed inspection due to excessive rust on frame which rendered unsafe to operate by the inspection station. this was previously reported however the vin was not correct.

The rust on the frame of my 2004 4runner is excessive and very concerning to me as i've had the local toyota dealership and my personal mechanic tell me not to drive it at all and if so keep it to a minimum. not sure what to do because that basically means the suv is no good... i was told there is a recall for that but after typing in my vin there was no frame recall... why is the rust so bad is my question and why are there other people dealing with the same thing, is also something i'm finding out. the suv's overall condition is great and it has fairly low miles (126,600) so the rust being so excessive is confusing. just looking for some help on what to do and what my options are because it's definitely a safety hazard.

The frame has so much rust on it and other areas of the undercargo that it has caused my speed and abs sensors to work improperly. speedometer will just quit working and abs lights will come on with the vcs trac, vcs off, and abs lights all coming on, then the engine light will also come on from time to time. there is already a hole rusted through the frame and mechanic said it was just a matter of time before it rusted through and broke.

My vehicle has excessive frame rust on the passenger side middle of frame and has a hole. i'm concerned the frame may split in half while driving.

2004 4runner sport v8 with 135mi. vehicle frame has rusted to the point that it will no longer pass pennsylvania vehicle inspection. vehicle has been deemed unsafe due to excessive frame rust. the extent of the rust is not commensurate with the age, mileage, or element exposure of the vehicle. the rest of the vehicle is in great condition and would otherwise be roadworthy for many years. as the sole owner, i have maintained this vehicle throughout its life and am disappointed to now have to manage a total loss.

Takata recall, performing routine maintenance on my 04 4runner, there is so much frame rust that i haven't been able to do any work without every bolt/screw/nut breaking off. the frame is so rusted i'm scared to drive it far if anywhere. i've taken it for service and have been told before that it's a road hazard and they were surprised nothing had fallen off and caused a wreck. please look into this, should have been included in the tacoma frame recall.

Frame excess rust

The frame on my 2004 4runner is badly rusted. there are rust holes where the cross member is welded to the frame therefore weakening the structure. this is a safety issue since there is no telling when that critical junction will break. another area of rust that causes great concern is on the front of the frame. the passenger side tow loop that was wielded to the frame has broken off with very little force. now what will happen if the 4runner is hit head-on. will the frame crumble like the frame is doing where the tow hook was located? the seams on the frame have some much rust that it is no longer safe for my wife and kids to drive.

Frame rust prevalent. there appears to be a few poorly designed areas on the frame that accumulate water and rust at an accelerated rate compared to other sections, namely: front radiator auxillary bracket that supports the front skid plate and trans cooler lines, and the sections of frame directly above the rear trailing arms, just after the transmission crossmember, and right before you get to the rear shock mounts. the front auxillary crossmember was poorly designed as there are 2 low points on either end with insufficient drain holes, thus water is trapped and causes corrosion over time. the rear trailing arm secitons are the same story, as water appears to pool in here and cause accelerated corrosion, where the passenger side is greatly affected as compared to the driver side which gets protection from the gas tank being in the way apparently. multiple forum searches and pictures from other individuals reinforces my thoughts. these areas of the frame needed better drain capabilities seeing as this is a boxed frame that on its own is apt to accumulate debris, road salt, and water.

Tl* the contact owns a 2004 toyota 4runner. the contact noticed that the subframe was rusted. the vehicle was not taken to a dealer. the vehicle was not diagnosed or repaired. the manufacturer was not notified of the failure. the approximate failure mileage was 167,000.

Hi, i recently purchased a toyota 4runner 2004 from a previous owner. i don't know much about cars and how the process works. but when the check engine light came on. i went to go take it to get it fixed as well as preparing the car for the smog test. which it failed, toyota the company was unable to fix due to having concerns of being liable and sued incase of a car accident. they also told me that i would have to be careful driving the veichle because a tire can break off. i am a college student and this was the only car that was in my budget. i really hope a recall goes out. i am afraid of my safety as well as others. thank you. i hope to hear a recall soon.

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 rust holes almost broke on right side and running threw on left

Tl* the contact owns a 2004 toyota 4runner. the contact stated that there was extensive rust on the frame of the vehicle. the vehicle was not diagnosed by a dealer. an independent mechanic diagnosed that there were massive holes and cracks in the front and rear of the frame, and the rear wheel well was rusted. the mechanic stated that the frame needed to be replaced. the vehicle was not included in nhtsa action number: dp18002 (structure). the manufacturer was notified and did not assist. the vin was not available. the approximate failure mileage was 194,000.

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.

Excessive frame rust, including holes, and general rust all around the frame. specifically in the front and rear.

My frame for my 2004 4runner are rotting and rusting away making it unsafe for me to drive.

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

My name is [xxx], i am here because of rusted frames i was just told today by aaa mechanic center in skoki illinois that i can not drive my 4runner home because isn't safe for drive, and they show me the frames both sides are rusted and i took the car to 6042 n western ave chicago il 60659 (773-728-5000) chicago nothside toyota at western ave and peterson in chicago illinois immediately and i was told isn't on recall. i contacted consumer affairs already and i will go to secretary of state on monday with the pictures to alert other owners. i will draft a letter to send with the pictures to the state representative as soon as possible because this need immediately attention. this suv is beautiful in and out but when they lifted the car up i was screaming because both frames was rusted. information redacted pursuant to the freedom of information act (foia), 5 u.s.c. 552(b)(6). *tr

We purchased a 2004 toyota 4 runner in may of 2017. the dealer informed us that his mechanic had checked the vehicle over and was in good shape and should last us a long time. on august 14, 2018 i drive the vehicle to a toyota dealership approximately 70 miles away to have diagnostics run on it for an issue with the 4-wheel drive. after placing the vehicle on a lift and checking it out, he had us step into the shop with the vehicle still on the lift to show us what he found. the frame had multiple rust hole through the frame and one running vertically along the transmission frame bracket. it was so bad he made us sign a waiver releasing the dealership from liability before he would let us leave with it. this is a limited edition, 2004 toyota 4 runner with a little over 156,000 miles on it. i feel that toyota should stand behind their products as apparently this is a well-known issue with these vehicles. we have had our grandchildren in this vehicle and the frame could have collapsed at anytime causing death or injury to any or all of us. we bought it because of toyota's reputation which at this point is not worthy of anything when they don't stand behind it. this issue should have been addressed before the frames reach this point of being beyond repair.

Severe frame rusting, with holes, some as long as 6", and would not pass pennsylvania inspection. had to have welded in 6 different sections.center front toe, left and right front harness, left and right frame center, and left rear frame end. the garage and autobody shop said toyota should be recalling the 4 runners for frame rust, not just the tacoma, tundra and sequoias. they have seen the severe rusting of the frame in the 4 runners. i have read numerous complaints of the 4 runner frame rusting. this is a dangerous situation!!! it needs to be addressed.

Rust on the frame including the rear bumper, crack in the dashboard from drivers side over to the center of car. drivers seat excessive movement at attachment between seat back and base on external portion of seat. the vehicle was parked at various times when inspected. repainted rims that paint had flaked and peeled.

The frame is rusted really bad. the bracket that holds the rear passenger side lower control are has rusted off making me tie it up and making it useless. the frame has several places that the rust has ate large holes in it. if you need me to i can mail pictures to you. i bought this 4runner brand new. i contacted toyota about this problem and they told me that the warranty has expired but that if i bought a new toyota then they would give me a 1000 dollar rebate as a goodwill gesture. i do not want the 1000 dollar goodwill rebate, i want my 4runner fixed.

My 2004 toyota 4runner was not able to get a brake job because the frame was rusted, rear trailing arm brackets broken off, differential housing on both sides broken, holes in frame right side. totally rusted and unsafe to drive.

I just discovered that the frame on my 4runner is severely rusted due to low quality steel. several mechanics have observed the frame and all of them have told me it is unsafe to drive. i have a 2003 toyota land cruiser and its frame is in great condition. both cars have been garaged and operated in the same conditions. the frame rust is so bad, it is difficult to get the car up on a lift to perform oil changes, etc. the main concern is safety. if the car is in an accident, i was told that it would not provide any protection from a side or front impact.

Took vehicle in for a repair recently at a toyota dealer upon tear down they told me that my 2004 4runner's frame and many other structural supports for the engine and mounts are not structurally sound due to severe corrosion. they found holes in the frame at engine cross member on the passenger side also found both rear body mounts and lower radiator support excessively rusty. they declined the repair work and told me the vehicle is unsafe to drive. i am the original owner and have taken great care of the vehicle as you can see in the attached photo the original paint is still glossy no rust on the outer body but extensive rust on the frame and underbody. i am greatly disappointed with the excessive frame rust because otherwise the vehicle runs well but of course it is not safe to drive according to the toyota dealer.

2004 toyota 4runner with significant rust on the underbody including frame. the vehicle is stationary but was deemed unsafe to drive due to frame damage. it has been well maintained and there are no other issues aside from significant rust damage.

The 4runner was well cared for and the frame has rotted to nothing in under 15 years. it is extremely unsafe and is the same issue present in the tacoma's and other toyota full frame vehicles. the rust develops early and in the same spots on all models. it spreads rapidly and compromises the entire frame making he vehicle unsafe to drive. i believe toyota has shown a pattern of neglect reguarding the manufacture of their vehicle frames and the 4runner is no exception.

Frame is rusted and warned will likely not pass state inspection when renewal is required in june 2019 by several mechanics

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.

Tl* the contact owns a 2004 toyota 4runner. while the vehicle was parked, cracks were seen in the dashboard. the dealer (zt motors of fort walton beach, 1000 n beal pkwy nw, fort walton beach, fl 32547, (850) 863-2167) was contacted, but the failure was not diagnosed or repaired. the manufacturer was made aware of the failure and did not assist. the failure mileage was 22,000. *tt updated 9/26/18*jb

2004 v8 4 runner with only 62,000 mi.,frame fracture right rear @ lower control arm attachment point. left rear of frame missing two sides @ wheel well and large hole at lower control arm attachment. advised by mechanic not to drive the truck. this is the same issue toyota had with the tacoma and tundra trucks of the same years. the frame is rusted to the point that the suspension that attaches to it will fall off. the rest of the vehicle has no rust and runs perfectly.. it was never in any accident and the paint and body are like new, but the frame members are completely rusted out. i would have never known about this dangerous condition if wasn't for my mechanic finding this during a routine maintenance.visit.

Excessive amounts of corrosion and rust on the vehicle's frame. frame welds are rusting through in various spots. i only have 112k miles on this vehicle. this amount of rust and corrosion is unacceptable.

Total vehicle frame is rusted through. not safe to drive

The frame has rusted on the passenger side where the frame is welded together. the chicago northside toyota dealer found it while doing work on my vehicle. it is about a 3 inch hole on the outside of the frame and there is also a rusted hole on the opposite side near the brackets. please see pictures attached. they told me it is unsafe to drive. they tried to get toyota to fix it because the sequoia and tundra have similar problems and were recalled. however toyota declined.

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

Frame is prematurely failing. there are holes rusted in the frame. this has been a known problem with other toyota models which utilize the same frame. toyota did a random "inspection" where they identified and fixed on piece of the frame but have failed to provide support for the entire frame. the car is now unsafe as it has failed a vermont state inspection.

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

My 2004 toyota 4runner will not pass it's next inspection due to a hole from corrosion in the frame. the hole is in the passenger side frame. the car is always kept in the garage, is washed regularly and all maintenance work has been done by a toyota dealer

My 2004 toyota 4runner will not pass it's next inspection due to holes from corrosion in the frame.

Upon pre-inspection of my personal vehicle for purchase i found that both rear corners of the frame were totally rotted out. upon further inspection, after removal of the rear bumper, it turned out that the rust extended almost entirely through the corners of the frame. there was also a major hole in the frame where the factory welds were conjoining pieces of the frame right where the exhaust bracket mounts to the right hand side of the interior facing of the frame. on the front end of the vehicle there was a massive rust hole extending along the right front factory welds connecting the right front body mount to the frame. the rear rotted corners of the frame underneath the bumper and right front body mount were repaired at my father's automotive service station by my dad who has more than 50 years of experience. with a vermont state inspection license it was concerning to him to see the rotting and rusting centralized around the factory welds, and occurring where the body of the vehicle is mounted to the frame and the rear bumper is preventing serious injury from impact due to a potential collision.

My 2004 well-maintained toyota 4runner's, with 170,000 miles, frame rusted so badly that it wouldn't pass the nys inspection. the frame on this suv is the same frame as the recalled 2004 toyota tacoma's, which were able to have there frames replaced due to rusting issues.

Flaking rusty frame. any undercarriage scratch immediately rusts

I have a 2004 toyota 4runner that i believe is too dangerous to drive due to the severely rusted frame. i have attached some photos to see for yourself. i contacted toyota twice to see if there's anything they could do and there was nothing. they told me to file a complaint with nhtsa. also i have had cars longer than this truck that have no frame rust and i live in the same area. therefore it can't be caused by the area i live in.

Vehicle frame has holes around high stress areas from severe rust and corrosion.

Toyota dashboard cracking / melting after toyota extended warranty ze6 closed out. this needs to be a recall i have seen dashboards that have melted and cause window glare. which affects drives ability to see.

Front right and left frame extension brackets rusted out and rotting. this is happening with many other owners and needs to be addressed.

Upon visual inspection frame found rusted through on right side just forward of rear axle and appears to have rusted from inside. suspect low quality steel was used. excessive rust on entire frame. body and mechanical systems are in excellent shape with 120,000 miles. toyota should be responsible for repairs as frame should last for 20 years.