Problems with 2007 Toyota FJ Cruiser STRUCTURE

Frame and parts badly rusted. pieces falling off. brake lines now rusting. frame badly rusted as well. internal fuel tank issues with corrosion

Severe rust on under-side of vehicle. suspension components at risk of detaching due to rust.

Excessive amount of rust for mileage of car 156k as of writing frame is flaking/scaling even after application of por-15 to try and salvage the frame to make it last a while longer. replacement of tank straps at 120k due to failure from rust. car will become unsafe to drive in a short period this seems to be a very common issue with this frame/year area as toyota already has replaced the tacoma frames that were rusting/rotting the same way.

Frame has a lot of rust. the straps to hold the gas tank broke due to rusting. rear bumper frame has also rusted.

On dec 30, 2019 i took my 2007 fj cruiser in for regular maintenance and shortly after i dropped it off, i was contacted by the dealership and asked to come back. they wanted to show me the bottom of the vehicle because they said it was no longer safe to drive. i went back to the dealership and the mechanic showed me that the frame of my fj was completely rusted through with multiple holes in right side of the frame - some holes measuring over 5 inches in length. it crumbled when touched. i was told that the rest of the vehicle was in perfect condition but it was no longer safe to drive because of the condition of the frame. i have found out since, that this is a known issue with the 2007 fj cruiser models but toyota has yet to recall the frames. i've also found out that they have recalled other models due to prematurely rusted out frames, but the fj's have not been included in those recalls. i was stuck in toronto unable to drive back to ny, so my family incurred massive unexpected costs to get home, and work & school were missed because of this situation. i've been told it will cost me approx $15 - 20k to get my truck repaired, but i believe that cost is toyota's responsibility. in the meantime it's unsafe to drive so i'm without a vehicle making my life and the life of my family more difficult seeing as it's our only vehicle... and it's stuck across the border in toronto, canada. i hope toyota recalls the 2007 fj cruiser model frames asap - i've learned that there are many other fj owners across north america who are dealing with this issue and are very unhappy with how toyota is dealing with it (or i should say seemingly not dealing with it). i don't feel my otherwise perfect vehicle should become an oversized paper weight when toyota has dealt with similar issues in other models - the solution is pretty clear.

The frame of my 2007 toyota fj cruiser is rusting uncontrollably. it was "descaled" and sprayed with protecting fluid. the descaling revealed significant frame rust. my passenger rear shock mount has rusted completely and the shock has become free from the frame. i have yet to get an accurate estimate of the damage but will soon

Bought my fj new in 2007.when i did i asked if they had rusty jones or undercoating and was told with the new alloys i didnt need it. 3 weeks ago i was having my mechanic check the brakes and he called me down to show me a break in the frame connecting to the body.thankfully he found it because i was supposed to go to boston the next day. the truck only has 139,000 miles on it and the frame is completely rusted out so its not safe to drive.i brought it to the dealer i purchased it from and 2 reps came down from nh to look at who basically told me i had a good ride with it and they would do nothing.i then called toyota cec and was told the same. i brought to a welder who specializes in this type of work and was told 5000+ in labor alone and thats without seeing under the gas tank so he said it wouldnt be worth it as he banged of the rust in other spots and there was no metal to weld to left.brake and fuel lines are swelled from the rusty metal tubing.i consider myself lucky as i often take my grandkids in the fj. so now im left with my other fj that i bought new in 2008 which is ok underneath.the issue is with all the 2007 fj frames like their tundras and tacomas. i have opened a case with toyota but there are so many there should be a recall as these are unsafe to drive.the body is ready to collapse on the frame. i was told privately that toyota chooses to ignore the issue as they no longer make the fjs but still sell tacomas and tundras. ## vin passed ## 2007 toyota fj cruiser ##

My gas tank straps completely rusted off leaving the gas tank hanging down below the frame and in extreme compromised unsafe position. multiple areas of frame rust completely through not supported by either end

Frame is rusting out- truck only has 142k on it. told today it will probably fail inspection next year as it barely passed today. this is a huge safety concern and affects the structural integrity of the vehicle toyota has settled with tacoma, tundra owners but ignores issue with fj

My frame has rusted tremendously to what i feel is a dangerous degree. there are holes through some frame rails and also some near the suspension mounting points. my fuel tank straps rusted to the point one rusted through and broke, the fuel tank was then hanging down close to the ground. not many miles have been driven per year on this vehicle.

My vehicle is prematurely getting eaten by a rapid and uncontrollably growing rust issue. this is very unsafe as the gas tank almost fell off while driving due to the straps being corroded and the frame is getting weaker to the point i can feel the body flexing in situations it does not need to be flexing.

I came back from a trip from florida driving and a wheel bearing went bad and i took it to a mechanic when i got back and he showed me more frame rust that connects to the lower control arm

A toyota dealer inspection of the undercarriage frame of my toyota fj cruiser, reflects that the vehicle is no longer safe to drive. the vehicle has always been maintained by the dealership and is otherwise in good condition. the rust is severe in the frame pillars, joints and attached components. in the event of an accident, the vehicle would not protect passengers because the frame would quickly disintegrate. the toyota dealer stated that unless toyota issues a recall the cost to replace the frame is at least $15,000.

While driving normally and less than 10 miles per hour, thankfully on a regular, paved, local road with little traffic, the driver side rear suspension spring seat and stabilizer bar attachment point on rear axle suddenly, unexpectedly, and without warning just tore apart and off of the axle housing to which it was mounted and the resulting sharp and heavy metal edged parts completely sheared off a brake line releasing all hydraulic brake fluid and causing the immediate loss of all normal braking ability. thankfully nobody was injured, but the car can't be driven at all now, because it has no brakes at all, other than the mechanical emergency brake, and by using transmission "braking." lots of rust under car since we bought it used from dealer in morristown nj, apparently due to low quality steel used in initial construction and apparent lack of adequate factory anti-rust treatment of frame and other undercarriage parts. interior and painted top body parts show no rust issues. however, the underside, is full of lots of rust. this is apparently a well-known, very common problem with toyota fj models. it is very dangerous, and it should be addressed by toyota immediately! i'm making plans to have the car towed to a local toyota dealership for inspection and possible repairs. finally, as far as i am aware, this car has never done any significant or taxing "off-roading."

Frame is rotted to the point of being very unsafe

Frame completely rusted away from body of car. engine and exterior body are in perfect condition due to the rusted out frame toyota claims the car is unsafe to drive and they will not touch it. see attached . the frame looks like a pastry would as it flakes away in layers until there is nothing left.

Rotted rust issue all over the undercarriage.

During 2019-2020 state inspection of 2007 fj cruiser with 78000 miles by dealer was told that frame is so rusted that it probably would not pass the next inspection. explanation given was that toyota does not make their frames as thick as other makes. this vehicle was used as a daily driver, not much off-road and no serious off-roading. i work from home, so most years less than 5000 miles driven. also have had to replace front brake calipers for the past 3 years.

The vehicle has been taken good care of but, the frame is prematurely rusting at connecting points to the body causing the vehicle to unsafe to drive. the vehicle looks and runs well but might be a safety risk in sudden stops of accidents causing vehicle body to dislodge from frame.

The frame of my 2007 toyota fj cruiser is heavily rusted and rusted through in several areas.

2007 toyota fj cruiser, 125k miles. mid-atlantic area of the us. frame has excessive rust and degradation. a toyota dealership during a normal service visit and 2 independent mechanics confirm it is unsafe to drive or to especially tow trailers. both independent mechanics also added they have seen this issue before on tundras, fj cruisers, and 4runners from the same era. weldments in the frame are corroded and riddled with cracks. large sections of frame members are also very corroded with thin walls/holes. biggest concern is loss of structural integrity which could lead to a major mechanical failure/accident. little to no rust on the body, have driven other toyota and ford trucks in same environment with no rust issues at 200k miles. filed a complaint with toyota.

The tank straps are rusted out. one is completely broken, the other is 75% broken, and the safety of driving it is compromised.

Frame is rusting & cracked in various places. gas tank strap rusted / corroded completely off leaving gas tank sagging in the rear. this has all happened over time.

My fj cruiser frame is rotting from the inside out, the gas tank mounting strap has broken and due to frame rust, the mounting point has failed and broken off the frame. the rear body mounts are deteriorating as is the rear frame cross members. due to the frame ruat and gas strap mounting point failing, the dealer cannot repair. this is a safety issue as the gas tank cannot be correctly mounted. of the 2nd gas tank strap fails, the gas tank may fall out. i have seen several bodyshops that are surprised at the age of the vehicle and the amount of frame rot present.

Excessive rust of the frame. have found multiple holes in structural areas such as the transmission cross member welds meeting the frame. failure of the frame coating all over. frame rot from the inside causing holes from the inside out. also rusting from areas such as control arms, rear end links, and differential mounts. will provide more pictures when i have the availability to do so.

I have been dealing with rust on the frame the frame is rusting from the inside out also dealing with rust on the tank straps

I have had two brake lines burst in the past year due to rust. both times i was lucky to not have been on the interstate and was traveling at a low speed. both have been the back brake lines. this rust situation with the fj's is unacceptable and dangerous! toyota should be held accountable and the situation needs to be addressed before a person is killed or seriously injured.

I am reporting the issue of frame rust and corrosion of the fuel tank straps. the amount of corrosion and frame flaking is alarming and poses a huge safety issue for my family, other drivers and myself. since purchasing the vehicle i have done everything i can to maintain and fix this issue including complaining to toyota themselves with little to no success. the amount of rust compared to my other vehicle is completely out of proportion. body mounts are flaking and crumbling and the frame is corroded and falling apart from the inside out.

Frame has completely disintegrated where the rear upper control arm links meet the crossmember, making the vehicle unsafe and fail the nh state inspection. the links broke free while driving on a rural road. upon further inspection we found rust perforation on frame rails with thin and fatigued metal in the same general area.

I bought a 2007 toyota fj cruiser and the body was in perfect shape couple months go by and i took it to my mechanic and he points out how i have a hole in my frame and as well and a hole where the welds to the frames are as well

While driving, my exhaust broke from hitting a pothole. when i took to the shop for repair, we noticed so much rust on the frame. i made an appointment at my local dealership to have it inspected, we found that the frame is extremely rusted with holes in the back piece by the bumper. the local dealership opened a case. they also said for me to contact corporate toyota and open a case. the local dealership said they take this extremely serious because of the tacoma rusted frame recall. the dealership said they can not make a decision and that it must be made by corporate. the dealership supplied the pictures so corporate could see the frame rotting. i stayed in constant contact with a dealership representative the entire time. every conversation that i had with toyota corporate ends with them saying 'sorry, there is not a recall right now'. the dealership representative became frustrated and even said she would not put her kids in the fj cruiser because its unsafe. everyone agrees that a 2007 fj cruiser frame should not be rusting out like this. finally, the dealership was who told me i should contact nhtsa and start this process. i have been reading on fj criuiser specific forums recently about others having the same issue. it seems really wide spread.

Received word from toyota service department that the frame on my 2007 fj is rotted, not repairable, and unsafe to drive. this seems to be a manufacturing defect, not owner caused. looking to toyota to address the problem. this seems similar to the tacoma frame recall.

The frame on my 2007 fj cruiser is so badly rusted that the brackets connecting the rear control arms to the frame deteriorated and they are no longer attached. this was noticed when the straps from the gas tank also rusted away and the gas tank dropped. the frame damage is so severe that no body shop wants to touch it for liability reasons.

Excessive frame rust rear body mount .

Rust on frame and underbody of vehicle corrosion beyond normal for vehicle

Took the vehicle in for oil change and check a transmission fluid leak. dealer found large amounts of rust on frame and suspension and noted, "not recommended to drive."

Frame rust - frame is rusted so bad mechanic and local deal said vehicle is not road worthy. if i had not taken my vehicle to a mechanic before service and general maintenance repairs, i would have driven on a 2400 mile vacation across country without knowing the danger of a failing frame. my initial complaint is i was unaware of any frame issues with toyota trucks, there should have been a general recall/inspection of all toyota frame vehicles for safety inspections. second complaint is there is no resolution at this time, mechanic said it could take months to get an answer from toyota and even then not sure they will fix it. now i am without a vehicle.

The national highway traffic safety administration needs to open an investigation into reports of frame rust and corrosion problems for the 2007 ' 2014 toyota fj cruiser. this is the same ongoing safety problem as the several past recalls on other full framed toyota vehicles. excessive frame corrosion 'rot' starting in jointed metals within the frame structures is rusting from the outside and the inside out. in recent observations non-jointed rust metal is also suffering rust through in other parts of these frames. my personal vehicle exhibits all the signs of excessive rusting including one rust through hole at the rear cross member location underneath the rear bumper. this location is neither accessible nor visible without the bumper removed. the opposite side of the cross member exhibits large sever flaking rust present both outside and inside the frame. the main frame, location behind the front wheel, exhibits severs large flaking rust inside the frame. the outside within this area also contains a half size dollar rust area through the first frame layer that initially appeared as surface rust. in conclusion what appeared as normal surface rust can indeed be structural integrity concerns. the frame is rusting inside out at an alarming fast rate, much faster than the 60's fj40 frames i have restoration experience with. i was informed per my dealership the rust would be documented but not considered abnormal and no recall was in place.

A few weeks ago i was working on my vehicle and i had to remove the rear bumper then i found the chassis damaged by so much deep rust, that for a moment i just thought to brush and put an anti corrosive but the damage is not fixed with brushing and painting. i call toyota for a frame recall and they don't have any yet. my vehicle it's not safe to pull anything. i also feel that one of these days the body can be detached from the chassis.

Cracked secondary structure within the engine bay on both the driver side and the passenger side.

A major hazardous issue was the fuel tank strap broke due to rust and had to be replaced. fortunately for me a mechanic spotted this serious problem before a potential disaster happened out on the highway. the entire frame of this vehicle is rusting at outstanding speed and presents a safety issue for myself and others on the road. toyota has presented a record of using inferior frames in the past and unfortunately the fj vehicles were given those inferior, unsafe frames as well.

I currently own a 2007 toyota fj cruiser that has very bad rust problems. i have included photos. as you can see from the photos the vehicle has been very well taken care of inside and out. i own a 2014 highlander, and have owned a scion and avalon and none have had any rust issues. i had intended to tow a boat with this but after a toyota of kingsport dealer rust inspection he said, 'there is a large amount of rust under the truck, it is not safe to tow with because of rust damage. there appears to be other rust damage to critical areas of the frame'. i have had other mechanics look at it and they all agree that the frame needs to be replaced, and anything touching it that is rusted. one mechanic noticed that the vent for the rear differential was rusted over preventing it from venting properly. we replaced the rear differential fluid but he said it may be in poor shape also. i believe this is an unusual amount of rust and is due to materials of construction problem or poor rust coating from the factory. i think that toyota might want to investigate this vehicle and determine why it rusted so badly. if you need additional photos or information just let me know. i realize some of this is surface rust.

Vehicle is showing excessive rust on the frame and under-body. i have an older vehicle that almost has no rust. rust on the 2007 fj cruiser is mainly on the frame joints and the rear axle. car was daily commuter for about 5 years and then became a leisure vehicle driven mainly on weekends and outings.

Tl* the contact owns a 2007 toyota fj cruiser. the contact stated that the muffler and entire frame were corroded and deteriorated when touched. the contact called dch freehold toyota (located at 4268 us 9 s, freehold, nj 07728, (732) 810-1048) and was informed that they could not assist. the contact was advised to call the manufacturer. the contact called the manufacturer and was provided case number: 1905240531. the manufacturer referred the contact to nhtsa. the approximate failure mileage was 101,000.

Replaced rear differential $2,500, was advised when picking up the car the frame has rotted out. mechanic advises life of vehicle approximately 2 years. we would have never repaired the vehicle had we known. i have been advised this is a known toyota problem.

Frame has rust throughout. had to replace gas straps because rusted through and broke. repair axel bearing.

I was driving approximately at 30 miles per hour, in a residential street, when suddenly i heard a noise and noted that the windshield developed a five inch crack, starting from the bottom center going up. a few days later, the crack moved significantly, to the left and right of the windshield moving to cover the entire windshield. there was no prior damage to the windshield, the vehicle has never been in an accident and it has never been taken off road. the crack seems to have developed due to pressure stress- a defect from manufacturing. there are numerous other reports from other owners of this type of vehicle with similar reports, often times, even after having the windshield replaced. this is a safety concern and manufacturing error.

While driving at 25 mph, i hit a relatively small pothole on the road. immediately as the vehicle went down on one side, the windshield cracked, about 4 inches from the middle bottom up. there had not previously been any damage to the windshield and nothing hit the windshield during this incident. the following day, the entire windshield cracked entirely, from the left to the right. after being inspected by the toyota dealer, the windshield has to be entirely replaced at owners cost. the vehicle has never been off road, nor was this an accident or a major incident. the vehicle has never been in an accident. toyota knows of the problem that due to the way the vehicle was manufactured, there is potential for the windshield to crack. i also sent a report to toyota informing them of this problem.

Frame is severely rusted, has cracks & corrosion, & is unsafe to drive

Recently i noticed my fj cruiser has inner fender cracks under the hood inside of the engine compartment, bigger than 5 inches long, on the both sides of sheet metal of the fender, and the hood has bulges also at both sides. i call toyota and told them about this problem, and they just told me that my vehicle has a chassis and this should not bother me. also they tell me that my vehicle is not under warranty, so they cant do anything about it. i do a search over the internet for inner fender cracks, and found this to be a recurrent problem in the same place that cracks occur on the fj cruiser, some vehicles cracks are bigger and some are smaller, but it is just matter of time to happens. i am not a car technician, but i am really worried about my safety and the safety of my family, so i opt to not drive with my family members, i don't really know if those cracks can make the vehicle collapse at the front. i really need some professional help.