2003 TOYOTA 4RUNNER Structurebody Problems

Severe frame rust. 2 large holes on the inside of the frame just back from the front wheels and 2 large holes at the ends of the rear crossmember.

Toyota has had issues with their frames rusting out and the 4th generation 4Runner is not exempt from this issue. My 2003 is requiring extensive work to keep it on the road safely due to frame rust. A recall to replace frames should be in place.

There is major corrosion on the chassis, brake-power steering-transmission lines, and all metal brackets on the frame and engine. The corrosion is so bad there is holes on the chassis. Known issue, many complaints, Toyota Corp. says to keep calling back maybe something will be done in the future. Unable to upload photos!

Severe frame rust, there was a recall for tacomas but 4Runners have the issue just as bad

Extensive rust through out frame, resulting in holes in structural members. Leaving frame in a weak and vulnerable state.

I purchased this 2003 Toyota 4Runner in 2018 under what I assumed was prime condition, for a vehicle that spent the majority of its life in Nebraska/Kansas before I moved to Texas in 2021. At 87,400 miles at the time of purchase, the vehicle had no visible damage to the exterior besides a few paint chips, some minor hail damage and scratches, and some easily fixed surface rust in the paint on the tailgate. The previous owner had driven it leisurely and had kept the miles low after 15 years. The car has had some mechanical issues, but nothing out of the ordinary outside of some regular maintenance over the first few years. Being close to 100,000 miles, the timing belt and pump was replaced around 98,000 miles. Other issues have been fixed periodically, please reference the attached files. After joining a Toyota 4Runner 4th Generation Facebook group and seeing...

Vehicle frame has rusted through and has holes affecting structural condition.

Excessive frame rust causing difficulty to keep vehicle on the road. No warning lamps, I noticed the rust starting years ago, now the rust is so bad that the frame is rusted through causing difficulty steering and loud crunch noises. I contacted Toyota Consumer Affairs explaining the rust concern and asked if I needed to take the vehicle to a dealership for inspection, they said it wasn’t necessary (sounds like they don’t want to admit the existence of a possible manufacturing defect). The vehicle is available for inspection. I feel like I would be doing a disservice to society if I continue to drive this vehicle on public roads due to the danger of injuring a pedestrian or another motorist.

So much rust has developed the frame is literally giving out. Toyota admitted to a rust issue- it’s now a safety issue with this generation of 4Runner. They did a recall on the same frame for Tacoma but not 4Runner.

The frame of the car has been rusting at a significant rate in the last 4 years. Mechanic identified major rust issues that would make the vehicle not safe in case of an accident.

I have two 2003 Toyotas, a tundra and 4runner. The 4Runners frame is rusting out everywhere including the welds. My mechanic said it was getting to the point that it’s dangerous to drive and if it was in a wreck the frame would likely fail under the stress. My tundra frame from the same year is immaculate. I believe the are similar frames. This is obviously a defect in the production based on my readings and is very common. The investigation was opened in 2018 and its now 2022, when will this get addressed!

Frame has major rust holes towards the front inside next to the catalytic converters. Hoping to get them repaired before frame failure. The frame design is similar to the 2005 to 2015 Tacomas, which experienced similar issues with rust damage causing frame integrity issues. Toyota had a program to replaced those frames, but not for the 4Runners. The issue seems to be caused by certain factory openings in the frame that allow road salt to enter into the frame cavity, and cause the inside to rust. Being next to the catalytic converter, the heat accelerates the rust. On my 4Runner, the issue has gotten worse in the last 2 years. I cannot understand why Toyota covered all other trucks/suvs that use this similar frame but ignored the 4Runner.

The frame on my 4Runner is rusting through in multiple locations. The rear of the frame has already failed and a trailer I was pulling dragged on the road heavily as it failed. Definitely at risk of caving in long before the engine or transmitoo fails.

The frame on my vehicle is rusting prematurely. It's doing this on many other 4Runners and other Toyota trucks.

The frame of the vehicle is rusted to the point my fist can fit through a hole in the frame.

The frame on the vehicle is rusting out. If not repaired, serious injury could occur if the frame breaks. A compromised frame could cause serious injury if an accident occurs. The driver side main frame has a gaping hole on the inside and another hole forming underneath that is in close proximity to the larger hole. The entire back cross bar member supporting the bumper is rusting out as well as the front cross bar member. The vehicle was inspected in July 2020 and the dealership said the frame was OK and had plenty of life left in it. After getting a muffler installed at a local independent shop in October 2021, the hole grabbed the attention of the technician. After inspecting, rusty flakes kept falling away.

Extreme frame rust. The vehicle has extreme frame rust and Toyota should be held accountable for poor quality frame material. I have heard tons of stories of other peoples steering components snapping due to rust and frame damage.

I own a 2003 Toyota 4Runner with very low mileage for its age. It has been garage kept for most of its life. I was experiencing difficulty steering, and when I took the car to a mechanic, it was determined that the frame was prematurely rusted and rotted to a dangerous level putting my life at risk while driving it.

The frame is rusted very bad and it’s a major safety issue for this type of vehicle I don’t know when it’s going to fall apart. I am sure I am not the only one to have this problem.

Vehicle frame and suspension components are completely rusting out. Having issues with the corroded steering column lower shaft not allowing the vehicle to turn properly.

At the end of June 2021, while driving I experienced a loud clunk and grinding noise, with reduced control of steering and brakes on my 4Runner. I took the 4Runner to a Goodyear Automotive Service Center on Woodward Avenue in Royal Oak, Michigan, who told me that the vehicle was not driveable due to severe rust damage of the frame that resulted in a broken sway bar. I thought I should take it to the closest Toyota dealership in Troy, Michigan for advice and they responded that the vehicle was beyond repair and that a new frame would cost around $20,000. I could not leave my car there, and risked driving it home, where it has been parked ever since.

The frame of my 4runner is so so rusted that my mechanic put his finger through a piece of the frame it is so unsafe for Mr and my grand children and EVERYONE ELSE on the road that it literally makes me sick. It'd the only vehicle I have so I have NO CHOICE but to drive it. It terrifying. It is available to inspect at anytime. I just bought this vehicle less than a year ago from a dealership and it so sad that they wld sell it to anyone knowing the frame was rusted its criminal in my opinion. It Is for sure a safety hazard to everyone. I hope that this investigation proves to help get all of these 4runners OFF THE ROAD. So that a preventable tragedy doesn't happen.

Really bad frame rust, holes in frame, engine mounts.... Cracked dash board. All problems shared by many 2003 4runner owners too. I'll take more photos.. Thanks for your attention.

Due to severe rust underneath the vehicle, there have been a few issues that have made the vehicle very unsafe to drive. Last week, both of my rear brake lines were completely done and leaking brake fluid leaving me with no brakes. This was due to rust and corrosion that had eaten the metal lines away. The radiator mounts are corroding, as well as the skid plate for my fuel tank and a few spots on my frame near the rear. I was not aware of the rust as I just got the vehicle a few weeks ago. I was driving in traffic when my brake light came on and I noticed my brakes didn't seem to be very effective and they eventually got the point where they were not working or slowing the vehicle at all. Once I took it to the shop and they put it on the...

Car inspection at a service center revealed advanced rusting of the frame. I was told this could be dangerous.

The frame is completely rusted through and soon will be unable to support the steering, engine or drive train. The problem was confirmed to me by an independent service center that I have used for 10 years and I trust.

The frame has rusted almost completely through near the front upper and lower control arms near the cross member there. The passenger side is so bad the welder I took it too sad he couldn’t repair it without doing the crossmember section and all. The driver side is not at bad but doesn’t look to hot. The crossmember where the radiator sits is also starting to completely rot away

I heard a loud noise (scraping-dragging) from the bottom of the engine area while driving on the highway This was a very dangerous and scary incident Pulled over and My fiancé checked under the engine A very large metal piece was dragging the road I did not hit a bump or anything. A body shop mechanic informed me that the chasis of the 4 runner was in extremely bad condition The 4Runner will not pass inspection because of this condition I respectfully request help in this matter

Frame rusted to the point the shop won’t fix the brakes and allow me to drive the car. The brake line rusted through since it was attached to the frame and when repairing the brakes they found the frame rusted too bad and coming apart. Looking online this seems to be a common problem with this year Toyota 4Runner.

Three mechanics said the frame was rusted with holes and is unsafe to drive. The vehicle is not inspectable, so had to have mechanic weld Steele on frame to be able to pass inspection.

I HEARD THERE'S AN INVESTIGATION ON THESE FRAMES SO MINE IS ROTTING AWAY

TL* THE CONTACT OWNS A 2003 4RUNNER. THE CONTACT STATED THAT WHILE THE VEHICLE WAS BEING REPAIRED, HE WAS INFORMED THAT THE UNDERCARRIAGE AND SUBFRAME OF THE VEHICLE WAS EXTREMELY RUSTED. THE VEHICLE HAD NOT BEEN TAKEN TO A DEALER OR INDEPENDENT MECHANIC TO BE INSPECTED. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 139,000.

IN REFERENCE TO NHTSA ACTION NUMBER: DP18002. MY MECHANIC INFORMED ME THAT MY 2003 4RUNNER IS STARTING TO EXPERIENCE EXCESSIVE CORROSION ON THE FRAME. HE INFORMED ME THAT THIS IS COMMON WITH THIS MODEL. I CONTACTED A BODY SHOP TO INQUIRE ABOUT POSSIBLE SOLUTIONS. I WAS INFORMED THAT THEY GET INQUIRIES ABOUT THE 2003 4RUNNER OFTEN YET THEY DO NOT LIKE WORKING ON THEM AS THE FRAME IS CONSTRUCTED IN SUCH A WAY THAT IT IS DIFFICULT TO ADDRESS THE CORROSION ISSUES. I'M REPORTING THIS TO HELP FACILITATE THE ONGOING INVESTIGATION AND TO INQUIRE ABOUT ANY PROGRESS BEING MADE ON THE INVESTIGATION.

I HAVE BEEN IN CONTACT WITH TOYOTA SEVERAL TIMES OVER THE PAST 4 YEARS ABOUT RUST ISSUES WITH THIS FRAME, BUT THE REFUSE TO FIX IT. THEY RECALLED THE TACOMA, TUNDRA AND SEQUOIA OF THE SAME YEAR FOR THIS REASON. THE FRAME RUSTS AND FALLS APART. WHILE DRIVING UP MY ROAD I FELT THE REAR OF THE CAR SHIFT TO THE SIDE, I TURNED AROUND AND WENT STRAIGHT HOME TO FIND THE FRAME AT THE REAR PASSENGER TIRE BROKEN. I HAVE ATTACHED A PICTURE OF THE BROKEN AREA, BUT CAN SEND MORE PICTURES OF THE ENTIRE FRAME IF NEEDED.

THE FRAME IS RUSTED BEYOND REPAIR AND THE VEHICLE HAS SPENT THE MAJORITY OF ITS LIFE IN A N UNDERGROUND GARAGE PROTECTED FROM THE ELEMENTS, AS WELL AS IN FLORIDA. IT HAS VERY LOW MILEAGE, AND NO OTHER SERIOUS PROBLEMS.

WE BOUGHT A USED TOYOTA 4 RUNNER IN SEPTEMBER 2017 FROM A USED CAR DEALER. THE VEHICLE LOOKED GREAT AND DROVE AMAZING BUT AFTER HAVING IT SERVICED WE WERE INFORMED THAT THE VEHICLE WAS RUSTY ON THE FRAME AND TO KEEP AN EYE ON IT. OVER TIME THE VEHICLE GOT WORSE AND WE HAD IT LOOKED AT AND WERE TOLD IT WOULD NEED TO HAVE A FRAME OR BE REPAIRED. ESSIMATE AROUND $5000 SINCE THE VEHICLE WAS FINANCED WE DONT FEEL SAFE DRIVING IT AS WE WERE TOLD IT IS UNSAFE. WE DONT HAVE THE MONEY TO BUY ANOTHER VEHICLE IS THIS COVERED UDER THE LEMON LAW. TOYOTA WIL NOT DO ANYTHING REGARDING THIS. BUT IT IS CLEARLY A DEFECITIVE PROUDUCT. THEY WERE RECALLS DONE ON TOYOTA TRUCKS WITH THE SAME ISSUE BUT NOT THE 4 RUNNER. PLEASE ADD ME TO ANY PENDING LAWSUITS REGARDING THIS ISSUE. [XXX] INFORMATION Redacted...

FRAME IS RUSTED OUT, EXCESSIVE RUST THROUGHOUT THE ENTIRE FRAME AND SUSPENSION COMPONENTS. SWAY BAR MOUNTS FOR REAR AXLE HAVE RUSTED OUT VEHICLE IS UNSAFE TO DRIVE

OUR 2003 4RUNNER FRAME IS RUSTED THROUGHOUT. NOT EVEN SAFE TO DRIVE WITH 127,000 MILES. THE CONTROL ARM IS READY TO FALL OFF. THANKFULLY, A BUSTED BRAKE LINE GOT US INTO THE SHOP BEFORE A BAD ACCIDENT HAPPENED. NOW WE'RE LOOKING AT SPENDING $4000 ON FRAMEWORK TO MAKE IT SAFE TO DRIVE. SO SAD THAT THIS ISSUE HAS BEEN KNOW FOR YEARS AND NO ONE IS MAKING TOYOTA MAKE IT RIGHT. PLEASE DO SOMETHING BEFORE PEOPLE GET HURT. WE WERE READY TO TAKE A 1000 MILE TRIP FROM ALABAMA TO TEXAS WHEN WE FOUND OUT ABOUT THE RUST. MY MECHANIC STUCK A PENCIL THROUGH THE FRAME! IT'S SOOOOO BAD! PLEASE DO SOMETHING!

THE WHOLE UNDER SIDE OF THE VEHICLE IS RUSTED. IT CAN'T EVEN BE DRIVEN. MY BRAKE LINE BUSTED THE OTHER DAY (WITH MY KIDS IN THE CAR) AND CAUSED ME TO LOSE THE USE OF MY BRAKES. WE ARE OKAY, AND THE MECHANIC WAS ABLE TO REPAIR THE BRAKE LINE. BUT MY MECHANIC WAS ABLE TO STICK A PEN THROUGH THE FRAME. HE SAID WITH THIS EXCESSIVE RUST, I SHOULD FILE A CLAIM. AFTER SEARCHING ONLINE, IT SEEMS THAT THERE HAVE BEEN RECALLS ON OTHER MODELS OF TOYOTA BECAUSE OF RUST. HOPING YOU CAN INVESTIGATE AND MAKE THIS RIGHT. THANK YOU!

EXTREME CORROSION OF FRAME AND BRACKETS

THE FRAME OF MY CAR IS CORRODING AT AN ALARMING RATE AND EVEN AFTER TREATMENT IT CONTINUES TO RUST TO THE POINT WHERE MY CAR IS NOT SAFE TO DRIVE

MY 2003 TOYOTA 4RUNNER'S FRAME HAS OUTRAGEOUS RUST ISSUES. I HAVE AS BIG AS QUARTER SIZE HOLES THAT HAVE RUSTED THROUGH IN THE MIDDLE OF THE FRAME ON THE PASSENGER SIDE AND DRIVER SIDE. THIS IS MY FAMILY CAR TRANSPORTING MY KIDS AND IS UNACCEPTABLE FOR TOYOTA TO HAVE KNOWN ABOUT THIS FOR YEARS AND REFUSE TO RESOLVE IT.

EXCESSIVE CORROSION ON FRAME. THE SKID PLATE HAS FALLEN OFF THE VEHICLE DUE TO ROTTEN CONTACT POINTS ON THE FRAME. SECONDARY FRAME ELEMENTS HAVE FALLEN OFF THE VEHICLE IN TRANSIT DUES TO CORRODED WELDS. MULTIPLE MECHANICS HAVE TOLD ME THIS IS A WELL KNOWN AND COMMON PROBLEM WITH THESE VEHICLES.

TL* THE CONTACT OWNS A 2003 TOYOTA 4RUNNER. THE CONTACT STATED THAT THERE WAS FRAME CORROSION ON THE UNDERSIDE OF THE RADIATOR. THE VEHICLE WAS TAKEN TO THE LOCAL DEALER. THE MANUFACTURER WAS INFORMED OF THE FAILURE AND INFORMED THE CONTACT THAT THERE WERE NO OPEN RECALLS FOR THE FAILURE. THE FAILURE MILEAGE WAS APPROXIMATELY 128,000.*DT CONSUMER STATED TWO MAIN SUPPORT AREAS IS SEVERE CORROSION JUST LIKE THE RECALLED TACOMA'S.*JB

REAR OF THE FRAME IS RUSTED OUT THERE IS A BIG HOLE IN THE SIDE OF THE FRAME. I JUST BOUGHT THIS VEHICLE AN I LOOKED AT IT BEFORE I BOUGHT IT AN LOOKED AT THE FRAME JUST FIGURED MAYBE THE REST OF THE FRAME WOULD BE FINE BUT IT WAS NOT.

REAR DRIVER SIDE CONTROL ARM BROKE OFF AT THE FRAME AFTER STRIKING POTHOLE AT HIGHWAY SPEED. AFTER THE FAILURE THE VEHICLE WAS VERY HARD TO CONTROL AND ALMOST LED TO A ROLLOVER. THE VEHICLE WAS UNABLE TO BE DRIVEN AND HAD TO BE TOWED. TOYOTA RECALLED TUNDRA'S, TACOMA'S, AND SEQUOIA'S FOR FRAME REPLACEMENT SO IT IS A KNOWN PROBLEM. WILL TOYOTA BE HELD LIABLE FOR ACCIDENTS RESULTING FROM PREMATURE FRAME FAILURE? BY RECALLING THE OTHER MODELS THEY OBVIOUSLY ACKNOWLEDGED IT WAS A PROBLEM AND 4RUNNERS SHARE THE SAME PLATFORM AS THE TACOMA SO WHY WERE THEY NOT INCLUDED?

SEVERE RUST.

SEVERE RUSTING ON THE FRAME. HAS GONE COMPLETELY THROUGH THE FRAME.

WE RECENTLY PURCHASED A 2003 TOYOTA 4RUNNER LIMITED. GREAT VEHICLE WITH THE EXCEPTION OF THE FRAME RUSTING AND HAVING WEAK SPOTS. WE HAVE DONE SOME RESEARCH AND THIS SEEMS TO BE A COMMON ISSUE WITH THE THIRD AND FOURTH GENERATIONS. THESE ARE BUILT ON A TRUCK FRAME AND THE TOYOTA SEQUOIAS, TUNDRAS AND TACOMA'S HAVE BEEN RECALLED FOR THIS ISSUE.

EXCESSIVE RUST / ROT ON THE FRAME LIKE THE TACOMA, SEQUOIA, AND TUNDRA. TOYOTA HASNT PUT ANYTHING OUT FOR THE 4RUNNERS. FOUND DAMAGE 31OCT2020