2004 TOYOTA 4RUNNER Structurebody Problems

What component or system failed or malfunctioned, and is it available for inspection upon request? Response: Frame, Suspension, Airbags / Yes it is available for inspection. How was your safety or the safety of others put at risk? Response: Safety was put at risk due to frame & suspension failure due to severe rust. Also due to failure of deployment of AirBags. Rusted Frame Failure subsequently caused safety of Injured Party and other motorists to be at risk due to the Injured Party’s 4Runner to dart across oncoming lane of traffic with no warning other than a swaying motion felt immediately before losing control. Once the Injured Party lost control of the 4Runner it crossed into oncoming traffic, progressing into the drainage ditch on the oncoming traffic side of highway. Once the 4Runner impacted the drainage ditch at a 90° angle, the 4Runners momentum dispersed by causing the 4Runner to...

2004 Toyota 4Runner SR5 - Frame rust: currently not drivable due to complete breakage from the rust. Driving 2 hours home on the highway I almost lost control, pressing/releasing the brake and/or gas pulls the steering side to side and sways the truck (fish tail) due to damage from the frame rust/breaking. There is no control of the rear end. Truck was in great condition prior to the frame snapping. Vehicle has been inspected by multiple mechanics (including Firestone, Welding/fabricating Auto Repair shops and small owned mechanic shops), possibly won’t be able to weld due to the amount of rust. Firestone won’t perform any service if the vehicle needs to go in the air (tires, oil..etc) due to frame rust. This has been a huge problem with Toyota, they addressed other models around the same year but excluded the 4Runner for unknown reasons. The dealership will not address the issue...

Frame rust. Huge problems on the 4th gen 4runners. Can't believe there's not a recall on this issue.

The undercarriage is full of rust that the repair shop will not test drive or fix due to the issue. No warnings.

Extensive frame rust to the point of structural failure. Cannot support weight or force.

Rusty frame undercarriage. It’s not going to get any better due to the fact I have to drive on hwy 80 with all the construction, that’s a hazard itself, potholes everywhere that puts stress on your frame and the salt every winter.

UNKNOWN: Excessive frame rust. frame is excessively rusting to the point where the brakes and suspensions is connected to the frame has been compromised. brake lines rusted to the point of failure, thus almost causing a wreck. Vehicle is now parked due to safety concerns involving the excessive rusting that is happening to the frame and any components that is attached to the frame.

Undercarriage frame rusted to the point where structural rust was formed in various places This rust has made a whole and cracks to the frame causing my vehicle to become a safety hazard on the road

Cars frame is rotting out to the point it is not safe to drive. I was told being in a collision could cause catastrophic failure and the car is just turning 20 years old with 125,000 miles. Can’t get my money back and the car is otherwise is excellent condition.

Took 2004 Toyota 4Runner SR5 to Toyota dealership to be serviced. Dealership called me to explain unable to do alignment, due to rear back frame excessive rusted through. Dealership advised waste of money to align new tires just purchased, unable to even do alignment and it was dangerous. Now what is to be done? This is my daily driver for work. How did this happen that its unsafe and dangerous to drive.

The rear tailgate window shattered while vehicle was in driveway as soon as it was turned off. Before it shattered there was an odor of something like plastic burning. Fortunately no one was hurt by the exploding bits of glass. The sound the breaking glass make was loud and startled the passengers. Good thing the vehicle was not in motion on the street or highway. On the internet I saw where other people shared the same problem on their Toyota 4Runner. Then I saw that Toyota had put out, TSB-0189-17, which stated exactly what happened to my 4Runner. Due to this possibly dangerous incident this should be upgraded to a vehicle safety recall.

2004 4Runner rear hatch glass imploded with rear defroster on while driving and glass shattered all inside the vehicle in the back behind rear passenger seat. The loud sound when it imploded sounded like we had got shot at and scared all four of us in the vehicle thinking we were shot at. We pulled the vehicle over at the nearest pull over while driving on a coastal two lane road. We searched for any possible bullets. Did not find any and had to clean up as much possible of shattered glass that had covered all of our clothing and belongings. Had no materials to cover the rear broken window and had to continue our drive to meet family members to attend an early event at 9:00 am.

Unknown: we were on [XXX] when the car went out of control. It first spun one way and then the other way and then we hit the concrete abutment where the guardrail connects to it. We hit it head on. It was as if we were on ice or oil, unable to gain control or brake. We checked the road and it was dry. Other cars were going by with no problem. The airbags didn’t deploy. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

Rusted frame

The frame of the vehicle rust just as same as the 03-09 Tacoma and there is nothing I can do the fix it and if I get new parts it ruins my Parts after a short period of time

The frame of my Toyota 4-Runner has developed holes making it dangerous to drive.

Frame and body prematurely and aggressively rusted despite constant care and upkeep. Toyota recalled the exact frame on their Tacoma of the same years and did not recall the 4runner frames. It’s criminal and dangerous to the user and other vehicles on the road.

-The frame is rotted out - If the frame were to break, which my mechanic i saying is very possible, a massive incident could occur - It has been confirmed by an independent service center - It has not been inspected by the manufacturer but is an astonishingly common issue Toyota is very aware of that they continue to ignore. - There were not indicators notifying me of the issue. I wanted to replace my suspension and the mechanic advised not doing so because of the rot.

The frame is damaged from excessive corrosion. The rear cross member that supports the trailer hitch and rear bumper is almost non-existent, which could result in the loss of the trailer being towed, and it will reduce the truck's rear impact resistance. The front right lower control arm has a 2'" x 3/8" lateral hole from corrosion, which could result in a catastrophic failure of the right front suspension system. The longitudinal frame members are compromised by corrosion which has penetrated through the steel in various locations. The front cross-frame member that supports the radiator is severely corroded. The frame to body mounts are showing signs of excessive corrosion which could result in the separation of the the body from the frame in an accident.

The frame is showing significant rust damage throughout the frame. A hole was punctured in the passenger side while using the factory bottle jack. This could have ended badly if someone was underneath when this happened. Furthermore there is deterioration on the front and rear sections that are questionable as to their integrity and resilience in the event of a crash. It is generally accepted by other owners of this generation that lack of adequete drainage throughout the frame has led to water pooling inside and creating excessive rust issues from the inside out.

The truck frame is rusting and making the vehicle unsafe prematurely. My vehicle only has 78 thousand miles and likely needs the frame replaced like many other toyota vehicle because of the lack of corrosion protection.

We took our 2004 4Runner for annual vehicle inspection and the service provider told us the vehicle would not pass safety inspection due to the excessive rusting on the steel frame and the suspension of the vehicle. Welding and patchwork will not fix this issue. My husband depends on this vehicle to work. The attached pictures give a small window into the extent of the damage. There is no current recall for this vehicle and year, but similar Toyota trucks from the same time frame have been recalled for the same exact issue. The entire frame needs to be replaced or worst case scenario, the vehicle is no longer usable. Toyota needs to remedy this issue for their loyal customers immediately.

The body frame is the problem, it has rust all around, the radiator supports are all rusted out almost hanging, front side of the frame and rear side are clearly rusted. Radiator could fall any time. The problem was confirmed by auto shop and inspection shop (independent service center). Vehicle has not been inspected by police or insurance representatives. There were no warning lights or symptoms prior to frame failure, for now.

The frame of my 2004 Toyota 4Runner, which is manufactured by Dana Holding Corporation, is the primary support structure of my vehicle, to which every piece is attached. It is the main protection against injury in a car accident. The excessive rust corrosion of the frame on my Toyota 4Runner greatly hinders the safety, crash-worthiness, and stability of my automobile, as transmission mounts, essential suspension components, and engine mounts are attached to it. Consequently, as it becomes affected by rust, it is significantly more prone to failing to protect me, the driver, in a car accident, and, furthermore, it can also cause serious accidents in and of itself. Depending on the gravity of the impact, not only myself but my passengers (my young children) can experience a wide range of injuries and even death. Because the excessive rusting of the undercarriage of my Toyota 4Runners can cause plenty of vehicle...

The body is excessively rusted through. Other vehicles this age or older do not have any where near the amount of excessive rust and holes. Parts have fallen off. Anytime the shop has to work on the truck, there is a pile of rust under it. Broken off rust poses a hazard to owner and others on the road as debris. Known issue on an uncoated frame.

Extreme Rusting on the frame undercarriage of the vehicle. Our mechanic found it today - said it must have been rusting for years & that this is a common problem with 03 - 05 Toyota 4Runners.

The chassis is completely rusted/rotten, 1" Holes throughout the chassis and was told that it won't pass inspection.

Unaware of frame rusting issues to vehicle.. Observed rust through carpet on driver side. Upon research safety is a concern. Due to high volume of this type of issuing occurring a safety recall should be issued. It was not verbalized at time of purchase the make and model of vehicle have these type of issues. Especially, when this issues had been occurring prior to purchase of this vehicle.

The frame is rusted through on this 4Runner. Same frame as the tacomas that were recalled and I’m wondering why Toyota wouldn’t recall THE SAME EXACT FRAME WITH MAJOR RUST ISSUES on a different platform. This truck is not abused so it’s very frustrating to see it falling apart at the frame when everything else is intact and solid. The rot on this frame is inevitable. I’m going to be very upset if I have to pay out of my own pocket for something that should be 100% covered under recall. This is a huge safety hazard and could lead to serious injury or death.

Under body has severe frame damage from rust.

The frame is rusted completely throughout. VERY DANGEROUS!

Vehicle has a rust frame which causes a dangerous

Rear section of the frame snapped in half during normal driving. Barely driveable extremely hazardous and will remained parked.

Took vehicle for service a couple of days ago. Mechanic would not work on the vehicle due to extensive frame rust and corrosion. Mechanic said he could push his finger through some of the rusted frame members. Extensive frame rust/corrosion on at least 3 sides of the vehicle and sagging frame in the front per mechanic.

Original owner of 2004 Toyota 4Runner SR5 (purchased February 23, 2004). Garage kept and approximately 125,000 miles. Vehicle was taken to mechanic for exhaust issues and reported the flange had rusted and disintegrated providing $2300 quote to repair. Taken to a second shop that indicated rust on frame and sub-frame was significant and would not accommodate an exhaust repair. Also stated that bolts and supports for radiator and gas tank were severely rusted. Estimates the car to be road worthy for an additional 3-6 months.

My Frame is a rusted mess. The entire frame is experiencing rust issues. My rear sway bar rusted off and broke into pieces (1/15/21). Now my exhaust pipe has fell off the muffler due to rust (7/21/21). My brake calipers have been very badly rusted as well as the pieces that hold my shocks and suspension in place. It has been progressively getting worse over the past 3-4 years. I feel like this has now become a safety issue and I'm not sure if it's safe to drive. It may be a risk to myself and other drivers on the road. My mechanic has told me that it will not improve and he thinks that the frame and other parts should be recalled. I have plenty of photos if needed. Please help me before something goes wrong.

My 2004 Toyota 4Runner has holes multiple inches in diameter rusted completely through the frame in multiple locations including where frame rails meet and are welded. This 4Runner is very clean and well kept in a climate controlled garage. The 4Runner was somehow not captured in the class-action law suit against Toyota that included the Tacoma, Tundra and Sequoia. Toyota has long known the frames are prone to excessive, premature rust corrosion because the frames were not properly prepared and treated against rust corrosion when they were manufactured and yet it has failed to offer significant help to owners. The excessive rust damage on my Toyota 4Runner compromises the vehicles safety, stability and crash worthiness because important suspension components, engine mounts, transmission mounts and body mounts anchor to the vehicles frames. I have spoke with a local Toyota dealer who stated they would inspect the vehicle with a diagnostic fee...

Last year the frame showed rust and holes and was rejected by the inspector. We were able to get the worst hole patched and it passed inspection. I am afraid the car might be unsafe.

On April 14, 2019, I was informed by an auto repair shop that my 2004 Toyota 4Runner showed signs of excessive rusting on the front end of the frame at the bumper and radiator support. The repair shop owner/mechanic indicated the bumper may eventually fall off. At the time, the odometer reading was only 117,834 miles. On June 22, 2021, I took the truck in to the Toyota dealer where I purchased it to have the regular oil change done and requested that they inspect the frame during the routine "Multi-Point Inspection." On this visit to the Toyota dealer, the truck's odometer reading was 141,595. The mechanic pointed out the more severe areas of rusting, which included the "Front right bumper support crumple zone area, also right side top under pass front seat area very thin." He indicated that the left side of the frame, although not as advanced as...

On April 17, 2019, I was informed by P.R. Auto Repair that my 2004 Toyota 4Runner showed signs of excessive rusting on the front end of the frame at the bumper support and radiator support. This observation was noted by the auto repair shop's owner. It is important to point out that my truck had only 117,834 miles on its odometer and should not already have had such a serious rusting problem. My truck was in for replacement of rear pads and rotors and was on a lift when the problem was noted. At the time the problem was being pointed out to me, a portion of the rusted metal in that area came right off. I was told that eventually the bumper could fall off and potentially lead to increased more dangerous problems. I have taken my 4Runner to A-1 Toyota where I purchased the vehicle for the regularly...

Severe rusting of body frame

The frame is rusted very badly and may need to be salvaged. Many of the other Toyota vehicles in this same year which have the same frame have already been recalled. Why not the 4runners? I've owned many other early 2000's vehicles and none have had this bad of rust. Simple not acceptable and not safe!

OUR 2004 TOYOTA FORERUNNER WITH V6 ENGINE WAS PURCHASED AS A USED VEHICLE IN 2019 WITH 106,000 MILES ON IT. SINCE THEN, IT HAS DEVELOPED MORE AND MORE AREAS OF RUST ON THE FRAME DESPITE OUR EFFORTS TO MITIGATE THIS ISSUE. WE HAVE HAD TO REPAIR THE FRAME, SUSPENSION, BRAKES, AND WHEEL BEARINGS. WE CONTINUOUSLY INSPECT THE UNDERCARRIAGE AND CONTINUE TO DISCOVER MORE AND MORE AREAS OF SIGNIFICANT RUST/DETERIORATION DESPITE EFFORTS TO CLEAN, TREAT (WITH PAINT, RUST INHIBITORS, WELDING REPAIRS). WE ARE CONCERNED THAT THIS DETERIORATION WILL SOON RESULT IN A CATASTROPHIC FAILURE AND POSSIBLE ACCIDENT RESULTING IN PROPERTY DAMAGE, INJURY, OR DEATH.

THE ORIGINAL FRAME ON OUR CAR IS ALMOST COMPLETELY RUSTED. THERE ARE HOLES IN THE FRAME AND COMPLETE CORROSION ALONG THE SIDE BEAMS. THIS IS A HUGE SAFETY HAZARD WHILE DRIVING. THERE IS SO MUCH RUST ON THE UNDERBODY. ALL PARTS ARE COMPLETELY STOCK AND ORIGINAL. THIS SHOULD NOT BE A PROCESS WE HAVE TO PAY FOR AS IT IS A MAJOR SAFETY CONCERN THAT TOYOTA IS COMPLETELY OVERLOOKING. THE HOLES IN THE FRAME ARE ABOUT A BASEBALL SIZE WHOLE. I HAVE TAKEN IT TO OVER THREE MECHANICS AND A BODY SHOP RECOMMENDED FROM TOYOTA AND EACH OF THEM SAID THE FRAME IS ALMOST ENTIRELY UNSAFE.

TOYOTA MADE GARBAGE BOXED IN FRAMES AND NOW MY TRUCK WON'T PASS INSPECTION

EXCESSIVE FRAME RUST CAUSING FRONT RIGHT FRONT BODY MOUNT TO DETACH FROM THE FRAME, PASSENGER FRAME RAIL HAS DISINTEGRATED BETWEEN CROSSMEMBERS. THE 4RUNNER HAS 170000 MILES ON IT WITH NO BODY RUST.

I HAVE ANOTHER 4 RUNNER WITH A HEAVILY RUSTED FRAME. I AM VERY CONCERNED THAT A UNSEEN FAILURE CAN OCCUR WHILE TOWING A 4300 POUND CAMER OR WHILE DRIVING ON ROUGH ROADS. I'M NOT ONLY CONCERNED FOR MY WIFE AND I BUT ALSO FOR OUR GRANDKIDS THAT VISIT US MONTHLY. HERE IS THE ACTUAL FAILURE. MY WIFE CAME IN LAST THURSDAY AND ASKED ME WHAT IS THAT CAR PART THAT FELL OFF? I WENT OUT TO CHECK AND FOUND THE RIGHT BODY MOUNT LAYING THERE. THE BOLT THAT HOLDS IT HAD ROTTED IN TWO BETWEEN THE UPPER AND LOWER RUBBER PIECES. THE BOLT AND NUT ON THE BOTTOM LOOKS GOOD SO THERE WAS NO INDICATION OF A IMMINENT FAILURE. I'M CONCERNED THAT OTHER MORE SERIOUS FAILURES CAN OCCUR.

EXCESSIVE RUST/ROT ON THE FRAME, WHICH IS LEADING TO EXPENSIVE REPAIRS AND FEARS OF UNSAFE OPERATION.

I PURCHASED THIS VEHICLE IN 2015 WITH 111K MILES ON IT. JUST FOUND OUT TODAY MARCH 2 THAT THE FRAME IS SHOT AND THE CONTROL ARMS FOR THE REAR AXLE HAVE LET GO ON BOTH SIDES DO TO FRAME ROT, THERE ARE ALSO OTHER QUESTIONABLE PARTS OF THE FRAME. SO VERY DISAPPOINTED IN THIS TOYOTA VEHICLE. THIS CAR COULDN'T EVEN LAST 20 YEARS, NOT THE REPUTATION OF WHAT I THOUGHT TOYOTAS WERE KNOW FOR.

MANY SIGNS OF PREMATURE RUST ON THE FRAME WITH SEVERAL HOLES. THE TRUCK ONLY HAS 124K MILES AND SHOULD NOT BE IN THIS STATE. TOYOTA HAS TO RECALL THESE FRAMES JUST LIKE THEY DO FROM OTHER TRUCKS MANUFACTURED DURING THE VERY SAME YEARS.