2005 TOYOTA 4RUNNER Structurebody Problems

- The undercarriage and frame have had premature rusting for years. The car is otherwise in excellent condition due to my care of it over the last 20 years. 5 years ago, a service person at my local Toyota dealership said, "I'm really disappointed in Toyota, I've never seen rust like this." I have now recently been told by a local service shop that it's time to get a new car. The lines are all corroded for the power steering, etc, and he was unable to even "touch them," and said that the rust issue is no longer safe, and we shouldn't drive far from home. - We are now unable to drive the car much, as we live in the country and have far communities. With a [XXX] , we are unwilling to drive the car over 45 mph, or more than 10 miles for fear of an accident...

When I first saw the pictures on the internet, I noticed that the front underside appeared to have rust issues. (Frontal shot) I contacted that sales person and he blew me off when I requested photos of the underbody. After several attempts, he finally sent a couple of pictures. The pictures obviously did not show the major rust issues as I have provided. The pictures were carefully fabricated not to show the major rust issues. It was apparent that the vehicle was taken off the internet while they hid the rusty underbody by applying some coating. A short time later, the dealership reposted the vehicle on their website. The vehicle was not properly advertised as having this major rust issue. I asked the salesman if his family was driving the vehicle, would he feel safe. He replied, "Absolutely". With this said, I decided to purchase the vehicle. Also, my signature...

Frame rot. The frame on the 4Runner is a known problem for excessive rot. My frame is shot. There is no reason a frame on a 2005 should be rotted. I was advised by my mechanic that my frame is dangerously close to snapping in half. This needs fixed by Toyota!

Under frame is rusted. The area between the doors in the passenger side is gone. only the top face of the member is present.

Frame has very severe rust and has started to come part in places. Soon vehicle will no longer be road worthy.

Frame of the vehicle is showing rust corrosion. The frame are the same as the tacomas that were released the same year. The tacomas were granted frame replacement by Toyota but 4Runners weren’t. Noticed a lot of other 4th generation 4Runners are having the same issues.

Frame on 2005 Toyota 4Runner has excessive rust due to Toyota’s negligence on frame production. I can make it available if needed. My safety is 100% compromised, had my mechanic not have told me of the issue, I would have kept driving the vehicle and the suspension could have detached from the frame at any point. The problem has been confirmed by my independent service center South Lake Automotive. It has not been inspected by police, manufacturer or other. There was no warning prior to the failure. Had I not had it pointed out as an issue, I would never have known it was an issue.

My frame has rotted through, causing the rear bump stops to fall off, putting excessive wear on both frame and suspension components. In parts of the frame, it has rotted all the way around and caused a loss in structural integrity. Worst of all, there is a hole near the rear most strap holding the gas tank to the chassis, which is a risk to not only me and my pregnant wife but others driving on the road around me if it where to fall off. Looking at the body, there is no rust or corrosion. The same goes for the engine bay, the rust is entirely located on the frame. Mechanically, the vehicle is in excellent shape. It has now got to the point it will no longer pass a NYS inspection.

Frame of the vehicle is rusting from the inside out. Upon inspection, holes in the frame are found, with many more hidden from sight. This is a disaster waiting to happen. This puts the driver and anyone else on the road at extreme risk if the frame breaks while driving. This problem is well documented with Toyota, and they have previously replaced Tacoma, Sequoia, and Tundra frames, but not 4runners. Everyone is at risk with these frames, even if it does not appear so. My frame looked solid until I began hitting it with a hammer and screwdriver and breaking away very weak spots of metal.

I took my vehicle into the Toyota Dealer after mechanic told my frame was rusting. The dealership confirm the frame is rusted. The frame of the vehicle should not be rusting out.

I own a 2005 Toyota four runner. The frame under the truck is completely rusted out everywhere. The car started swaying and I felt as though my vehicle was going to go out from under me. It felt like it was collapsing or melting underneath. This is my family vehicle. It was a dangerous situation and my entire family was in the vehicle. My spouse a children. I took it to a independent shop. The mechanic said that the frame had rusted out under the Toyota. He told me to park it and not drive it because it was about to split apart. He said that we were very lucky and just moments from a catastrophe. He also told me that their had already been a recall and replacement of the malfunctioning frames on Toyota Sequoia, Tacoma and tundra. In his professional option he thought Toyota should do the same...

The rear control arm broke while I was driving causing me to swerve uncontrollably and almost causing a collision

I have a 2005 4Runner with significantly rusted out frame that makes me worried about safety of driving it. I feel the amount of corrosion present is way beyond what I would expect for that year of vehicle

The frame broke loose from the rear sway bar due to excessive rust while I was driving it. My 4Runner is an 05 and has the same frame as the Tacomas of the same year, except with no recall. I believe it is wrong to recall the Tacoma frame and not the same 4Runner frame. It is available for inspection. The car wanted to loose control anytime the accelerator was pressed or released. The problem has been an issue for many 4Runner owners of similar years. There was no warning to this occurrence.

My 2005 4Runner frame is completed covered in rust and is corroding. Several places on the frame is rotting away.

Extreme rusting on frame and all parts under the carriage. Vehicle suspension and all moving parts underneath could fail or fall apart causing major accident or death to me or other vehicle.

Brought the car in for an alignment and I was told they couldn’t do it because of all the damage to the frame from rust, parts of the frame are not even there anymore, the front row hooks are gone, they said that all this damage ca impact the handle of the car and that it can’t be properly aligned and possibly won’t pass inspection.

Upon recent inspection of my vehicle, it was noted that the frame is severely corroded and rusted to the point where collapse or breaking of the frame is possible while driving. Apprently the frame was not properly treated for rust protection and can now be unsafe for driving. Enclosed are pictures of the rusted frame.

Frame and rear differential rust- extreme

Extreme frame rusting completely thru at the point of being unsafe and unable to put the truck on a lift for any repairs. A number of SAE mechanics warned me about driving this truck due to the extreme frame rusting. Sections almost completely separating apart. I have rust proofed and undercoated the under carriage at least three times. Toyota should make good on their negligence to properly rust coat their frames at times of manufacturing.

Really bad rame rust with holes through frame and frame components. I have pictures showing it’s the entire frame, not just the few spots. I had a shop replace the gas tank straps and when I picked it up they told me/warned me the frame had really bad rust. Have read about others having same or worse problems with chassis rust with this generation of 4Runners.

I would like to complain regarding my 2005 4Runner. Went to have the fluid changed at a dealership in the early part of July 2021 and they could not perform the service due to excessive underbody rust and corrosion . Therefore the I will have to find a service that can remove the corrosion to be able to have the shocks change, differential fluid change and to check and perform service on the brakes. The corrosion is starting to eat at the key components of the vehicle to the point where I may not be able to drive. Steering will be restricted and brakes will malfunction if they cannot get to the remove the areas to service the vehicle.

My frame is starting to rust very terribly no matter what i do to maintain it. The radiator support is completely rotted out and the rear part of the frame is getting worse by the month. This will cause a major injury in the case of an accident or the frame will break off while driving

Excessive frame corrosion. Mounting bracket that connects the lateral arm to the frame failed due to the deterioration of the frame. The rear axle is no longer perpendicular to the length of the car. I am experiencing a symmetric acceleration and braking performance and unpredictable steering.

I had my 2005 Toyota 4runner Limited serviced today. The mechanic will not work on the vehicle due to excessive rust and holes in the frame. The vehicle looks immaculate on the inside and out, but due to the corrosion underneath I am being advised to junk the vehicle as it is unsafe to drive.

PREMATURE FRAME RUST

EXCESSIVE RUST/CORROSION ON FRAME. HAVE SEEN STORIES WHERE FRAME SEPARATES FROM THE TRUCK BODY. UPON GETTING MY OIL CHANGE AT MY REPUTABLE ASE SHOP, OWNER POINTED OUT TO ME THAT VEHICLE IS RUSTING QUICKLY, HOLE IN FRAME, AND WILL NEED TO BE REPLACED SOONER THAN LATER ... WHEN I HAD IT UNDERCOATED, WASHED IT FOLLOWING EVERY SNOWSTORM AND ROADS SALTED, AND HAD PLANNED SINCE POINT OF SALE TO HAVE IT GO OVER 300,000 MILES AS SALES PERSON STATED WAS POSSIBLE.

RUSTY FRAME

I PURCHASED MY 2005 TOYOTA 4 RUNNER FROM THE ORIGINAL OWNER IN AUGUST. 2018 WITH 74,000 MILES ON IT. GARAGE KEPT AND OLDER COUPLE OWNED IT. INSIDE AND OUTSIDE ARE NEAR MINT CONDITION. NOW HAS 91,000 MILES. THE FRONT CROSS MEMBER IS COMPLETELY ROTTED AND BARELY BEING HELD TOGETHER. I CAN WIGGLE THE WHOLE PIECE WITH MY HAND. THE RIGHT SIDE CENTER OF THE FRAME HAS A 7 INCH HOLE ON HE BOTTOM AND A 2 INCH HOLE ON THE SIDE IN THE SAME AREA. THE RIGHT REAR CONTROL ARM BRACKET HAS ROTTED APART THUS THROWING THE THRUST ANGLE OFF AND THE STEERING WHEEL IS CROOKED WHEN DRIVING. THE FRAME SURROUNDING THAT AREA OF THE RIGHT REAR BRACKET IS COMPLETELY ROTTED AND SPLITTING IN 2. ALL GOT NOTICED WHEN I HIT A POT HOLE IN THE ROAD AND HEARD A CLUNK AND THE STEERING WHEEL WENT CROOKED. VEHICLE WOULD NOT...

SIGNIFICANT FRAME RUST THAT HAS CREATED FROM ROT WITH ROTTED OUT HOLES. VEHICLE IS NOW FAILING SAFETY INSPECTIONS. THIS IS IDENTICAL TO THE TACOMA/TUNDRA/SEQUOIA RECALL BUT THE 4RUNNERS WERE NOT INCLUDED IN THAT RECALL. THE 4RUNNERS SHOULD BE INCLUDED IN THAT RECALL OR A NEW RECALL ESTABLISHED SINCE THIS SAME FRAME RUST ISSUE IS SIGNIFICANTLY COMPROMISING THE 2005 4RUNNER (4TH GENERATION 4RUNNER) VEHICLE SAFETY PUTTING OWNERS AND OTHER DRIVERS AT RISK.

THE CHASSIS IS SEVERELY AND PREMATURELY RUSTED AND IS IN NEED OF REPAIR.

THE REAR WINDOW EXPLODED ON IT'S OWN WITH GLASS SHATTERING EVERYWHERE WHILE THE DEFROST FUNCTION WAS ON. THIS IS A VERY SERIOUS SAFETY ISSUE AND DESIGN FLAW THAT SHOULD BE REMEDIED BEFORE IT HAPPENS. TOYOTA ACKNOWLEDGES THE DESIGN FLAW YET ALLOWS THIS DANGEROUS OCCURRENCE TO HAPPEN WITH CONSUMERS BEFORE DOING ANYTHING ABOUT IT. THEY SAY TO BRING IT IN FOR INSPECTION BUT NOTHING THAT THEY CAN SEE UNTIL IT HAS EXPLODED. TOYOTA CUSTOMER SERVICE REPRESENTATIVE NAMED RYAN INFORMED ME TODAY THERE IS NOTHING TOYOTA CAN DO FOR ME. THEY NEED TO REIMBURSE CONSUMERS FOR REPLACEMENT NO MATTER THE TIME FRAME BECAUSE IT IS A SERIOUS SAFETY ISSUE AND IT IS A DESIGN FLAW!

MAJOR RUST/CORROSION ISSUES WITH THE FRAME MAKING IT UNSAFE TO DRIVE WITHOUT MAJOR WORK TO REPAIR

BROUGHT TO MECHANIC BECAUSE STEERING SUDDENLY BECAME A MAJOR PROBLEM. FRAME HAS DETERIORATED TO THE POINT THAT TRUCK IS UN DRIVEABLE PER MECHANIC. SUSPENSION COMPONENTS ARE COMING DETACHED, MAIN FRAME HAS HOLES AND FRONT FRAME IS COMPLETELY MISSING. MECHANIC SAYS HE HAS NEVER SEEN A FRAME RUSTED OUT THIS BAD IN HIS 30 YEARS ON THE JOB. HE SAID IT CERTAINLY SHOULDN'T HAPPEN TO A VEHICLE 15 YEARS OLD. AFTER RESEARCH IT IS FOUND THIS IS A MAJOR PROBLEM WITH THESE VEHICLES.

THE FRAME HAS EXCESSIVE CORROSION. I HAD SOME SUSPENSION REPLACED LAST YEAR AND IT WAS FINE TODAY MY DEALER TOLD ME THERE IS EXCESSIVE CORROSION AND RECOMMENDS NOT TO PUT ANY MONEY INTO IT. ALSO TOLD ME THIS HAPPENED QUICKLY BECAUSE IF IT WAS THERE LAST YEAR HE WOULD HAVE INFORMED ME THEN NOT TO DO THE SUSPENSION WORK.

UPON RECENTLY DRIVING A FAMILY MEMBER'S 2005 TOYOTA 4RUNNER LIMITED V8, I HEARD A KNOCKING NOISE COMING FROM THE FRONT OF THE VEHICLE OVER BUMPS. UPON INSPECTING THE VEHICLE, I DISCOVERED EXTENSIVE RUST ON NEARLY EVERY SINGLE PART OF THE STRUCTURAL FRAME, SUSPENSION COMPONENTS AND EVEN EXHAUST SYSTEM. SOME PARTS ARE SO BADLY RUSTED THAT THEY CAN BE PUNCTURED BY SIMPLY PUSHING YOUR FINGER THROUGH THEM (INCLUDING THE REAR FRAME CROSS MEMBER CRASH STRUCTURE BEHIND THE REAR BUMPER). THESE VEHICLES ARE RUSTING SO TERRIBLY THAT I'M SHOCKED NHTSA HASN'T FORCED TOYOTA TO RECALL THEM. YES, THEY'RE OLDER, BUT THE LEVEL OF RUST AND DECAY IS UNPRECEDENTED FOR NEARLY ANY MODERN CAR. TOYOTA ALREADY HAD TO RECALL ALL OF THEIR OTHER BODY-ON-FRAME VEHICLES (TACOMA, TUNDRA, SEQUOIA, AND LAND CRUISER) TO REPLACE THE FRAMES DUE TO RUST. WHY HAVE THEY NEGLECTED THE 4RUNNER WHEN IT'S ARGUABLY THE VEHICLE THAT WILL LIKELY SEE...

SWIPE TOYOTA FOUND SIGNIFICANT RUST OF MY FRAME. CAR HAS 142,000 MILES, LOCATED IN KENTUCKY.

I HAVE LARGE HOLES IN THE FRAME OF OUR TOYOTA 4-RUNNER. IT APPEARS THAT THE FRAME COULD SPLIT OR BREAK TO POSSIBLY CAUSE AN ACCIDENT. THE REST OF THE VEHICLE IS IN EXCELLENT CONDITION. IT SEEMS THAT SUBSTANDARD MATERIALS OR COATING WERE USED TO CAUSE THIS ISSUE.

MORE THAN ONCE A MECHANIC WORKING ON MY TRUCK SAID THERE IS EXTENSIVE RUSTING OF MY FRAME. I TREATED THE FRAME TWO YEARS AGO WITH RUST INHIBITOR AND 3M UNDERCOATING. THAT WAS THE SECOND TIME I UNDERCOATED MY TRUCK. I KNOW TOYOTA HAD A RECALL FOR THE FOR RUSTED FRAMES, THE SETTLEMENT COVERED TACOMA TRUCKS FROM THE MODEL YEARS 2005 THROUGH 2010, SEQUOIAS FROM 2005 THROUGH 2008, AND TUNDRAS FROM THE 2007 AND 2008 MODEL YEARS BUT THEY EXCLUDED 4RUNNERS. THERE SEEMS TO REALLY BE AN ISSUE WITH THE MATERIALS USED. I AM WORRIED THE FRAME WILL BREAK BEYOND REPAIR SINCE THERE IS NO GOOD METAL TO WELD TO.

FRAME IS RUSTED THRU ON BOTH FRONT SIDES WHERE THE CONTROL ARMS ATTACH

EXCESSIVE FRAME RUST AND UNDERBODY RUST. MOST WELD POINTS AND FRAME ASSEMBLY IS DEGRADING FROM RUST. TRANSMISSION COOLANT LINES HAVE CRACKED AND LEAKED.

EXCESSIVE UNDERBODY RUST, RUSTING FRAME JOINTS, AND ROTTING FRAME MEMBERS FROM THE INSIDE OUT.

I I WAS INFORMED BY THE TECH AT CHECKERED FLAG TOYOTA IN VIRGINIA BEACH , VIRGINIA THAT THE FRAME ON MY 2005 TOYOTA 4RUNNER SPORT HAS A FRAME THAT IS FAILING AND MAY PRESENT A DRIVING HAZARD IF I CONTINUE TO DRIVE IT . THEIR # IS (757) 716-5502.

WE RECENTLY PURCHASED THIS VEHICLE FROM A PRIVATE SALE AND WHEN THE MECHANIC LOOKED AT IT THERE IS A SEVERE AMOUNT OF RUST MAKING IT UNSAFE TO DRIVE. THIS IS NOT "NORMAL" RUST AND WE DO NOT WANT OUR 16 YR OLD DRIVING SOMETHING THAT COULD BREAK AT ANYTIME. I BELIEVE THAT THIS VEHICLE FALLS INTO THE LAWSUIT CATEGORY, FOR UNREASONABLE RUSTING. TOYOTA SHOULD HAVE TO FIX A FRAME, REGARDLESS OF AGE, IF THEY PUT BAD PARTS ON IT AND THE RUSTING ISN'T ALWAYS DETECTED IN THE EARLIER LIFE OF THE VEHICLE UNTIL IT BECOMES "UNSAFE".

2005 4RUNNER IN REALLY GOOD SHAPE EXCEPT FOR FRAME RUST. THIS CAR WOULD EASILY HAVE GONE ANOTHER 100K WITH A STRONG DRIVETRAIN AND INTERIOR IN GREAT SHAPE. WAS BROUGHT IN TO DEALER FOR MAINTENANCE AND WHEN THE TECH PUT IT ON THE LIFT HE SAW THE RUST DAMAGE. CALLED AND EXPLAINED THE ISSUE AND SUGGESTED THIS WAS NOT SAFE FOR THE ROAD. THIS COULD HAVE BEEN A CATASTROPHIC ACCIDENT IF BY CHANCE IT WAS NOT AT THE DEALER. RUST IS SERIOUS ENOUGH TO HAVE FRAME BREAK AND LOSS OF CONTROL OF VEHICLE. SO I GO FROM A RELIABLE GREAT VEHICLE TO A PIECE OF JUNK THAT CAN'T BE DRIVEN. THIS ISSUE SHOULD DEFINITELY BE COVERED AND REPAIR BY TOYOTA, AS TOYOTA IS FAMOUS FOR RUST ISSUES!!! THERE'S NO QUESTION THE FRAME WAS NOT COATED PROPERLY. RUST THIS SEVERE FOR A 2005 YEAR CAR IS NOT ACCEPTABLE. TOYOTA SHOULD STAND BEHIND...

IN NOVEMBER 2011, NISSAN RECALLED MY PATHFINDER DUE TO RUST CORROSION THAT COULD CAUSE THE FRONT SUSPENSION TO COLLAPSE. NISSAN BOUGHT BACK MY PATHFINDER, AND I USED THE MONEY TO PURCHASE MY 2005 4RUNNER. I HAVE DISCOVERED THAT MY 4RUNNER HAS A CORROSION ISSUE AS WELL. I HAVE ALSO DISCOVERED THAT TOYOTA KNEW OR SHOULD HAVE KNOWN ABOUT THE CORROSION ISSUE WITH ITS 2005 4RUNNERS AT THE TIME I PURCHASED MINE IN NOVEMBER 2011, YET I WAS NOT NOTIFIED ABOUT THE ISSUE AT THE TIME OF PURCHASE FROM THE TOYOTA DEALERSHIP OR AT ANYTIME SINCE I'VE OWNED THE VEHICLE. I WILL NOT BE DRIVING MY 4RUNNER, AS IT POSES A SERIOUS SAFETY RISK. IS THERE A PARTICULAR REASON WHY THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION IS TAKING SO LONG WITH ITS CURRENT INVESTIGATION CONCERNING COMPLAINTS OF FRAME CORROSION WITH RESPECT TO 2005 4RUNNERS?

THE AMOUNT OF RUST ON THE FRAME IS GETTING QUITE WORRISOME. THIS IS A KNOWN ISSUE AND RECALL WITH THE TACOMA, SEQUOIA AND TUNDRA, SO WHY NOT THE 4-RUNNER? THERE ARE HOLES STARTING TO FORM AND METAL FLAKES OFF ALL THE TIME. IT HAS GOTTEN TO THE POINT WHERE IT IS A LEGITIMATE SAFETY CONCERN. *TR

WE JUST HAD OUR 2005 TOYOYA 4RUNNER IN FOR THE YEARLY INSPECTION AND WERE TOLD THAT IT WILL NOT PASS INSPECTION NEXT YEAR AS THE FRAME IS RUSTED AND CORRODED OUT. WE BOUGHT THE VEHICLE USED IN 2017 FROM A LOCAL TOYOTA DEALER AND WHEN COMPLAINED ABOUT IT AT A ROUTINE INSPECTION WAS TOLD IT IS NORMAL WEAR AND TEAR. WE ALSO HAVE A 2000 LEXUS 300 NO RUST ISSUES WHAT SO FOR A VEHICLE 5 YEARS OLDER. I HAVE SEEN NUMEROUS COMPLAINTS AND EVEN A CLASS ACTION LAWSUIT AGAINST TOYOTA REGARDING RUSTING FRAME ISSUES WITH THE TOYOTA 4RUNNERS 2005-2011. OUR MECHANIC EVEN CALLED TOYOTA ABOUT THE FRAME RUST AND ISSUE AND WAS TOLD THAT THERE IS NOTHING THEY CAN DO. NOW I COMPLETELY UNDERSTAND THAT A VEHICLE OF THE AGE AND MILES(141,809) WILL HAVE ISSUES THAT NEED TO BE FIXED AND REPLACED, BUT TO HAVE THE FRAME RUST OUT...

HI, I OWN A 2005 4RUNNER AND I AM CONCERNED ABOUT THE HEAVY AMOUNT OF RUSTING ON THE FRAME. THE FRAME IS RUSTY WHICH IS CAUSING HEAVY FLAKING OF THE AFFECTED MATERIAL. THE BODY OF THE VEHICLE IS PRISTINE BUT I FEAR THAT THE PREMATURE RUSTING OF THE FRAME WILL AFFECT THE ABILITY TO SAFELY DRIVE MY 4RUNNER IN THE FUTURE. I AM A SPECIAL EDUCATION TEACHER WITH TWO YOUNG DAUGHTERS AND DON'T HAVE THE INCOME TO GO OUT AND REPLACE THE FRAME OR BUY A NEW VEHICLE. THIS 4RUNNER IS THE ONLY VEHICLE I OWN AND IS MY DAILY DRIVER. MY STUDENTS AND THEIR GUARDIANS DEPEND ON ME TO ARRIVE SAFELY TO SCHOOL EVERYDAY SO THERE IS CONSISTENCY IN MY STUDENTS' LIVES. I HAVE SEEN MANY 4RUNNERS IN THIS AGE RANGE SUFFER FROM THIS SAME CORROSION. I AM CONCERNED THAT MY FAMILY WILL BE INJURED IN A MINOR ACCIDENT...

I HAVE RUST THROUGH AREAS ON THE FRAME OF MY 2005 4RUNNER NEAR THE CATALYTIC CONVERTER. THE FRAME IS FLAKING AND PEALING AT THIS LEVEL. THE INTEGRITY OF THE FRAME IS COMPROMISED TOYOTA RECALLED TACOMA AND SEQUOIA FOR SIMILAR ISSUES BUT NOT 4RUNNER I LIKE THIS TRUCK BUT I DOESN'T SEEM SAFE DRIVING IT