2005 TOYOTA 4RUNNER Suspension Problems

ENTIRE body frame has excessive rust, holes, and cracks. It is available for inspection. Toyota dealership says it is safe to drive for now but it is failing. I feel any cracks, rust, holes, separation of frame components places all occupants and anyone near the vehicle at risk for when anything fails - this could be when the vehicle is on the expressway in motion (such as when the GM ignition switch failures happened), causing catastrophic loss of life, injuries, and damage to all. It's not a matter of "if" it happens, it's "when" it will happen. There are no warning lamps, messages, or other symptoms of the problem. The exterior, interior, braking, engine of the vehicle are in remarkable shape so it's very misleading. There are also 4runners on dealership lots that have significant rust, holes, and cracks in the frames that the dealership does not warn about, rather,...

Excessive frame rusting. There are holes in the frame from rusting. At this point in time there isn’t anything I can do about the issues. Frame is unrepairable.

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.

The contact owns a 2005 Toyota 4Runner. The contact stated while the vehicle was at the independent mechanic for servicing, and he was informed that the sub frame was severely corroded. The dealer was notified of the failure and referred the contact to the manufacturer. The manufacturer was notified of the failure and referred the contact to the NHTSA Hotline for assistance. The vehicle was not repaired. The failure mileage was approximately 166,000.

The frame on both sides of the vehicle in the front, where it connects under the radiator crossbar has rusted through.Not feeling to safe about this. also the transmission cooling lines are also looking thin. The dealership I have maint. done at informed me of this condition. Can send pictures if needed.

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.

Vehicle’s frame and suspension is showing major rust prematurely forming from the inside-out of the frame causing visible weakness in the structure of the frame that could cause engine or other suspension parts to fall off the frame of the car due to improper treatment of the frame. If I were to get in a car accident I don’t see the frame holding it’s structure. I would I highly suggest to have a safety recall done with frames with such damage.

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

The contact owns a 2005 Toyota 4Runner. The contact stated that upon taking the vehicle to an independent mechanic, she was informed that significant corrosion had developed on the front end of the undercarriage. The contact was then referred by the independent mechanic to the dealer where she was informed that while was rust found on the undercarriage of the vehicle, the vehicle was safe to operate and no repairs were needed. A month after the dealer inspection, the contact stated that an abnormal sound was coming from her brake pedal upon depression without warning. Once the contact made it home, she had the vehicle towed to an independent mechanic. The mechanic initially informed her that the vehicle was a total loss however, he and another mechanic were able to remove a large portion of the rust and replaced the brake pads, rotors, power steering line, hose, and brake pads....

Extensive, rapidly spreading rust throughout the vehicle's frame and fuel tank supports leaving little or nothing holding the fuel tank or areas of the suspension together. Vehicle cannot be safely placed on a lift for service because of thin metal in the bottom of the frame. .

TL* THE CONTACT OWNS A 2005 TOYOTA 4RUNNER. THE CONTACT STATED THAT UPON TAKING THE VEHICLE TO A-1 TOYOTA (50 AMITY RD, NEW HAVEN, CT 06515) SIGNIFICANT RUST WAS DISCOVERED ON THE SUBFRAME OF THE VEHICLE. THE MECHANIC FOUND A HOLE IN THE RADIATOR SUPPORT AND ANOTHER HOLE ON THE DRIVER SIDE FRAME RAIL. THE CONTACT WAS INFORMED THAT THE VEHICLE WAS SAFE TO DRIVE HOWEVER, THE PROLONGED RUST BUILD UP COULD LEAD TO A SEVERE MECHANICAL FAILURE. THE CONTACT WAS INFORMED THAT THERE WERE NO RECALLS ON THE VIN. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE BUT OFFERED NO FURTHER ASSISTANCE. THE FAILURE MILEAGE WAS UNKNOWN.

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...

THE FRAME UNDERNEATH THE FRONT BUMPER IS TOTALLY RUSTED AND CRUMBLING. MY MECHANIC SHOWED ME YESTERDAY AND SAID THE RADIATOR WOULD FALL OUT. ALSO THE CONTROL ARRMS TO THE FRONT TWO WHEELS ARE VERY BADLY RUSTED.

NOTHING HAPPENED YET BUT FOUND UPON CHECKING THAT THE REAR DIFFERENTIAL UPPER CONTROL ARM THAT IS ATTACHED TO THE FRAME IS RUSTED THROUGH. I AM AFRAID IT WILL DETACH WHILE DRIVING AND CAN CAUSE AN ACCIDENT. I HAVE REMOVED THE FLAKY METAL MYSELF IN THE SUMMER OF 2020 AND PAINTED IT TO AVOID FURTHER RUSTING. THE CROSSBAR IN THE FRONT THAT IS SUPPORTING THE RADIATOR IS RUSTED THROUGH AS WELL. THE METAL THAT IS HOLDING THE TANK IS GONE TOO.

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

TL* THE CONTACT OWNS A 2005 TOYOTA 4RUNNER. THE CONTACT STATED THAT YEARS AGO, AN INDEPENDENT MECHANIC DISCOVERED SEVERE CORROSION ON THE UNDERCARRIAGE OF THE VEHICLE. THE CONTACT RECENTLY HAD A FUEL LEAK FAILURE WHICH SHE LINKED TO THE CORROSION ON THE VEHICLE. NEITHER THE DEALER NOR THE MANUFACTURER HAD BEEN NOTIFIED OF THE FAILURE. THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS UNKNOWN. *LN*JB

FRONT FRAME RUSTED BEYOND REPAIR.

THE FRAME IS RUSTING AWAY

I HAVE A 2005 TOYOTA 4RUNNER PURCHASED NEW GARAGED KEPT WITH 66200 MILES WITH EXCESSIVE FRAME AND UNDERBODY RUST. I AM CONCERNED WITHOUT A FRAME REPLACEMENT FROM TOYOTA I WILL NOT BE ABLE TO DRIVE IT AS THE SAFETY CRASH STANDARDS NOT TO BE ACCEPTABLE AS NEW OR FRAME TO BRAKE AND CAUSE AN ACCIDENT.

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...

VEHICLE HAS VERY EXCESSIVE FRAME RUST. HOLES THROUGHOUT ENTIRE FRAME MAKING THE VEHICLE UNSAFE TO DRIVE. RUSTING FROM THE INSIDE OUT DUE TO NEGLIGENCE ON TOYOTAS PART. THIS VEHICLE HAS THE SAME EXACT FRAME THAT WAS RECALLED ON THE TACOMAS, TUNDRAS AND SEQUOIAS. PLEASE TELL ME WHY THE 4RUNNER WAS LEFT OUT?

EXCESS FRAME RUST. MECHANIC STATES FRAME HAS SEVERE RUST ALL OVER THE ENTIRE FRAME AND IS IN EMINENT DANGER OF COMPLETELY RUSTING THROUGH. MAJOR FRAME REPAIR OR REPLACEMENT IS NEEDED.

MY 4 RUNNER HAS EXTREME FRAME CORROSION DUE TO POOR QUALITY. THE VEHICLE IS NOW SUFFERING NUMEROUS SAFETY ISSUES AS A RESULT. THE FRAME IS NOT REPAIRABLE AND THE VEHICLE IS UNSAFE TO DRIVE. IT HAS LESS THAN 100,000 MILES. THE VEHICLE WILL NOT PASS STATE INSPECTION.

THE FRAME IS VERY RUSTY AND LOOKS LIKE IT'S GOING TO BREAK SOON. THIS IS THE SAME FRAME AS A TACOMA PICKUP

TL* THE CONTACT OWNS A 2005 TOYOTA 4RUNNER. WHILE DRIVING 45 MPH, THE REAR OF THE VEHICLE WAS MOVING. THE CONTACT STATED THAT THE SWAY BAR FRACTURED AND DETACHED FROM THE FRAME. IN ADDITION, THE TRACTION CONTROL AND TPMS WARNING INDICATORS WERE ILLUMINATED. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE DEALER AND MANUFACTURER WERE NOT CONTACTED. THE FAILURE MILEAGE WAS 125,000.

MY VEHICLE FAILED INSPECTION DUE TO A HOLE IN THE FRAME. MY VEHICLE HAS THE SAME FRAME AS THE TACOMA TRUCKS THAT HAVE FRAME ROT AND HAVE ALREADY BEEN RECALLED.

TL* THE CONTACT OWNS A 2005 TOYOTA 4RUNNER. WHILE DRIVING AT AN UNKNOWN SPEED, THE CONTACT HEARD A GRINDING METAL NOISE. THE CONTACT COASTED THE VEHICLE OVER TO THE SIDE OF THE ROAD AND NOTICED THAT THE ENTIRE FRAME WAS CORRODED. THE CONTACT STATED THAT THE FRONT BUMPER FRAME RUSTED OUT AND THE REAR PASSENGER SIDE FRAME SUSPENSION MOUNT WAS CORRODED THROUGH AND DETACHED. THE CONTACT STATED THAT THE REAR DRIVER'S SIDE FRAME SUSPENSION MOUNT WAS HEAVILY CORRODED, BUT WAS OK FOR THE TIME BEING. THE VEHICLE WAS NOT TAKEN TO A DEALER OR AN INDEPENDENT MECHANIC FOR DIAGNOSTIC TESTING. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 183,000.

FRAME BROKE LOWER CONTROL ARM CROSS MEMBER LEFT SIDE NO STEERING HALF PULLED OUT OF TRANSMISSION.

THE FRAM IS RUSTED AND NO TIME KNOWN WILL IT GIVE OUT N CAUSE SERIOUS ACCIDENT.

THE FRAME ON MY 2005 TOYOTA 4RUNNER IS SEVERELY RUSTED. I HAVE HAD MULTIPLE PIECES FALL OFF MY SUV, SOME WHILE DRIVING. THIS INCLUDES THE FRONT SKID PLATE, TRANSMISSION LINES, AND OTHER SMALL COMPONENTS. THE FRAME ON MY SUV IS COMING APART. RATHER LARGE PIECES ARE 'FLAKING' OFF. IT IS PLAIN TO SEE WHERE THE METAL IS SEPARATING. I RECENTLY DISCOVERED THAT THE FRONT IMPACT SENSORS HAVE RUSTED LOOSE OF THE FRAME AND ARE NOW DANGLING FREE. THIS LEAVES MY SUV SUSCEPTIBLE TO THE AIRBAGS NOT INFLATING DURING A FRONT-END CRASH. THE ABOVE HAS BEEN OCCURRING OVER THE LAST FEW YEARS. I HAVE OPENED CASE #1707170870 WITH TOYOTA, BUT THEY HAVE TOLD ME THAT THERE IS NO REMEDY FOR MY VEHICLE.

EXHAUST SMELL ENTERING CABIN, GETS WORSE WHEN ACCELERATING ON RAMP. EVEN WITH RECIRCULATION OF AIRFLOW HEAT AND OR AIR CONDITIONER STILL SMELLS BAD. I HAVE TO DRIVE WITH WINDOWS OPEN EVEN IN WINTER. ALSO RUST ALL OVER SUSPENSION, UNDERCARRIAGE. PLEASE TELL IF THIS IS A COMMON PROBLEM AND SAFETY RECALL. THIS STARTED SHORTLY AFTER PURCHASING THE TRUCK IN 2017 AND HAS GOTTEN WORSE SINCE. THE MUFFLER WAS REPLACED ALREADY.

TAKATA RECALL, I TOOK MY 2005 TOYOTA 4RUNNER SR5 TO A TOYOTA DEALERSHIP TODAY TO GET A TIRE ROTATION. THEY TOLD ME MY FRAME WAS TOO RUSTED OUT TO LIFT UP FOR FEAR OF HARMING MY CAR. I HAD NEW TIRES PUT ON AT THE SAME DEALERSHIP IN OCTOBER AND THEN NEW TRD WHEELS INSTALLED AT ANOTHER DEALERSHIP WHERE NOT A SINGLE MECHANIC MENTIONED RUST ON MY FRAME. APPARENTLY IT'S MY REAR PASSENGER SIDE THAT HAS IT THE WORST.

I TOOK MY 4-RUNNER TO MY MECHANIC ON APRIL 1, 2019 TO HAVE THE BRAKES CHECKED AND A CV BOOT REPAIRED. MY MECHANIC CALLED ME THE NEXT DAY AND INFORMED ME THAT THE MAIN SUPPORT BEAM OF THE FRAME ON THE PASSENGER SIDE WAS RUSTED OUT AND VIRTUALLY MISSING ON 3 OF THE 4 SIDES OF THE BEAM. HE TOLD ME THE VEHICLE COULD BREAK IN HALF IF I HIT A BUMP ON THE ROAD.

INFERIOR, STEEL, RUSTED FRAME AND SUSPENSION, TOO DANGEROUS TO DRIVE. CONSUMER STATED MY TRUCK IS BACK ON SHOP WITH STETLER DODGE THEY ARE RIPPING IT APART.*JB

THERE'S EXCESSIVE RUSTING OF THE CHASSIS, AXLE, DIFFERENTIAL AND OTHER COMPONENTS UNDER THE VEHICLE. I'M THE ORIGINAL OWNER AND OBSERVED RUST FORMATION WITHIN THE FIRST YEAR OF OWNERSHIP. THE SUV HAS ONLY 84K MILES AND IS GARAGED MOST OF THE TIME. I HAVE BEEN USING RUST INHIBITORS TO SLOW THE PROCESS.

2005 TOYOTA 4RUNNER SR5 WAS TAKEN INTO A CERTIFIED TOYOTA MECHANIC FOR INSPECTION AND THE MECHANIC SHOWED ME THE UNDERCARRIAGE OF THE VEHICLE, NAMELY THE FRAME AND OTHER ASSOCIATED PARTS. HE WARNED THAT IT WOULD BE DIFFICULT TO PERFORM MAINTENANCE ON THE VEHICLE IF THE FRAME IS ROTTED THROUGH. THE VEHICLE WAS PUT ON A LIFT FOR INSPECTION.

THE FRAME IS RUSTED OUT AT THE REAR AND AT THE RADIATOR SUPPORT AND AT THE REAR STABILIZER ON BOTH SIDES AND THE REAR BUMPER IS RUSTED INTO ON BOTH SIDES OF THE FRAME IN MY OPINION IT IS UNSAFE TO USE. MY WIFE HAD A CLOSE CALL WHEN THE REAR STABILIZER BROKE THE FROM THE FRAME ON BOTH SIDES

TL* THE CONTACT OWNS A 2005 TOYOTA 4RUNNER. THE CONTACT STATED THAT THERE WAS EXTENSIVE RUST AND CORROSION ON THE FRONT AND REAR SUSPENSION AS WELL AS THE FRAME OF THE VEHICLE. LANGWAY TOYOTA OF NEWPORT (285 E MAIN RD, MIDDLETOWN, RI 02842, (401) 619-5400) DIAGNOSED THAT THE FRAME AND REAR AXLE MOUNT WERE FAULTY, AND FURTHER EXTENSIVE SERVICING WAS REQUIRED. THE DEALER WAS NOT AUTHORIZED TO REPAIR THE VEHICLE. THE VEHICLE WAS INSPECTED AND DIAGNOSED BY AN INDEPENDENT MECHANIC. THE VEHICLE WAS NOT INCLUDED IN NHTSA ACTION NUMBER: DP18002 (STRUCTURE). THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE VIN WAS NOT AVAILABLE. THE APPROXIMATE FAILURE MILEAGE WAS 143,000.

2005 TOYOTA 4RUNNER 156K MILES WITH SUBSTANTIAL RUST AND CORROSION TO FRAME TO THE POINT WHERE MECHANIC CAN NO LONGER SERVICE THE VEHICLE.

SEVERE FRAME AND FRONT END RUST, VEHICLE WELL TAKEN CARE OF> SHOULD HAVE BEEN PART OF TACOMA RECALL!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!

SUSPENSION. VEHICLE USED IN THE NE US--MA. VEHICLE IS UNSTABLE AT HIGHWAY SPEEDS. WANDERS. IMPOSSIBLE TO KEEP STEADY. HEAVY RATTLE IN SUSPENSION AT ALL TIMES (FIRST NOTED IN 2015), EXCEPT ON VERY SMOOTH PAVEMENT. SIGNIFICANT RUSTING NOTED ON REPAIRS. MAY NOT PASS SAFETY INSPECTION. NO BODY RUST. MILEAGE LESS THAN 150K.

FRAME AND SUSPENSION MOUNTING POINTS RUSTED OUT CAUSING A SUSPENSION MOUNTING BRACKET FAILURE.VEHICLE WAS PULLING AWAY FROM STOP.

TOYOTA DEALER FAILED SAFETY INSPECTION DUE TO REAR SUSPENSION ARM RUSTED OFF AND A HOLE RUSTED THROUGH FRAME. ONLY HAS 124,000 MILES. TOYOTA SAID THAT VEHICLE IS UNSAFE TO DRIVE AND REAR END MAY LIFT DURING A HARD STOP. REAR BRAKE LINES ARE ALSO RUSTED OUT.

MY REAR FRAME ROTTED OUT CAUSING MY CONTROL ARM TO BREAK OFF. THE VEHICLE WAS EXTREMELY HARD TO CONTROL CAUSING A ROLLOVER ACCIDENT.

THE FRAME RUSTED THROUGH AT THE CONNECTING POINT OF THE REAR PASSENGER SIDE TRAILING ARM. MUCH OF THE FRAME IN THIS AREA IS SEVERELY ROTTED BY RUST. I NOTICED THAT THE VEHICLE WAS NOT TRACKING DOWN THE ROAD VERY WELL, WHICH WAS ABNORMAL. UPON RETURNING HOME I FOUND THE PROBLEM OF THE RUSTED FRAME.

THE REAR AXLE RUSTED SO BADLY THAT IT STARTED FLAKING APART. THE FRAME IS RUSTED SEVERELY IN THE AREAS WHERE THE REAR SUSPENSION COMPONENTS ATTACH. THE GAS TANK SKID PLATE RUSTED UNTIL IT BEGAN TO FALL OFF WHILE DRIVING DOWN THE ROAD AND ALL OF THE AREAS WHERE IT WAS BOLTED TO THE FRAME COMPLETELY RUSTED OUT. THE EXHAUST ALSO RUSTED THROUGH BEHIND THE MUFFLER CAUSING IT TO FALL OFF WHILE DRIVING DOWN THE ROAD. THERE ARE HOLES IN MULTIPLE AREAS OF THE FRAME. I HAD TO GRIND,CHIP, AND WIRE BRUSH THE FRAME WITH THE VEHICLE ON JACK STANDS IN ORDER TO REPAINT EVERYTHING AND KEEP MY VEHICLE GOING. THIS TOOK OVER 100 HOURS OF LABOR JUST TO COMPETE. I ALSO HAD TO REPLACE THE EXHAUST AND THE GAS TANK SKID PLATE. ALL OF THE BOLTS FOR THE SKID PLATES ON THE BOTTOM OF THE VEHICLE WERE COMPLETELY RUSTED THROUGH...

THIS VEHICLE HAS A VERY RUSTY FRAME. IT DOES NOT PASS STATE OF MAINE INSPECTION. LIKE MANY OTHER 4RUNNERS IT SUFFERS FROM TOYOTA'S FAULTY FRAMES. THIS TRUCK HAS NOT FALLEN APART AND CRASHED LIKE MANY SIMILAR UNITS. THIS ONE HAS A PERFORATED FRAME, AND DOESN'T PASS INSPECTION. WITH 80,000 MILES THE TRUCK IS LIKE NEW EXCEPT FOR THE FAULTY FRAME. THE RUST MULTIPLIES SITTING STILL OR TRAVELING. THE FRAME IS SO THIN IN SO MANY PLACES, THERE ISN'T PLACE TO MAKE SATISFACTORY REPAIRS.

THE FRAME OF THE VEHICLE IS RUSTED, THE RUST INTEGRITY MAY RESULT IN A STEERING FAILURE.