Frame is severely rusted and has holes started at 40k miles

- Sheboygan , WI, USA

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.

- Cornelius, OR, USA

I own a 2004 Toyota 4runner Sport Edition that suffers from frame rust issues. Mine isn't as bad as I've seen in person while working at a Toyota dealership as a tech or on the forums but from my experience in assisting in replacing frames at the dealership I know that my frame won't last very long. When I bought it from the original owner it had around 86, XXX miles on it and the typical spot in the from was rusted out. I choose to purchase it because it was the best example I could find, others having worse rust. I quickly discovered a weak spot which became a hole when trying to jack it up to do work along with chunks of rust that came off the rear end of the frame and all over. The weak spot that ended up being a hole seems to be caused by the AC drain location and how it drips right onto the frame which has an opening right by where it drips. I believe the drips went into the frame through the factory hole and lead to the weak spot and hole in my frame. I am not the only one who has experienced this issue. In fact on a Toyota 4runner forum there is threads on people extending the drain to prevent the same thing from happening to theirs or from getting worse. As a former Toyota tech who has seen how bad the frames that came in under recall and 4runner frames were first hand I cant believe that a the 4runner frames weren't included in the recalls. I've seen countless threads/reviews/complaints of severe rust causing accidents from suspension components. Toyota should be held accountable for the rust issues ont he 4runners just like the other vehicles. My 4runner now has 113, xxx on it and it will rust out long before the drivetrain gives out no matter what I try to do. My only option is to fix it using safe t caps when the time comes who makes frame fixes for Tacomas, Tundras, FJ crusier and of course the 4runner. They produce them for these vehicles because the frames rust out pre maturely. The rusty 4runner frames are a safety issue and should be addressed.

- Hyde Park, NY, USA

Entire frame of the vehicle is rotten with rust and holes. This vehicle has been inspected by McDaniel Toyota, Marion, OH 43302 and the damage was confirmed. I have been and must continue to drive this vehicle even though the dealership did not recommend it. No evidence of the extent of the rust and damage was not noticed until October 2023 when a strap on the gas tank came loose. Upon further inspection, he noticed the holes and rust all over the frame. Reported to Toyota because other 2004 Models were recalled for this issue. They were of no assistance.

- Morral, OH, USA

Frame of this vehicle completely rusted through. Holes on passenger side right where the front door ends. Hole is approx 12" long. Frame also has a hole in the left front core support. Advised that the vehicle is no longer safe to drive by my Toyota Dealer and personal mechanic.. There were no indications of this until a few weeks ago when the gas tank strap had come off and the gas tank was leaning. When inspected, it was found the frame was in disrepair.

- Morral, OH, USA

Purchased 4 runner from a Toyota dealer in 2018 with 130k miles. During routine maintenance in 2021 with 160k. The frame was found to have several holes and wide spread corrosion. It is absurd that Toyotas was let off the hook for frame replacements. I bought this truck from the dealer and it had structural frame issues that were not disclosed at the time of sale. Frames don-??t just fall apart apart in 4 years from normal driving. Clearly Toyota is ignoring the manufacturing deficits in there frames and still re-selling these as road worthy cars. It-??s absurd that Toyota was not required to replace these and not recall has been issued. People should not be able to buy/sell one off these vehicles they are not safe due to the frames rusting from the inside-out. They need to be recalled and removed from service.

- Oakdale , CT, USA

-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.

- Cambridge, MA, USA

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.

- Chesapeake, VA, USA

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

- Middletown, NY, USA

I bought my 2004 Toyota 4runner Sport edition as a new car, and have been the sole owner of the vehicle. I have taken good care of it the entire time. Regular car washes, service maintenance and necessary repairs over time. I recently had my 4runner in for repairs and spent a considerable amount of money, over $6,000 in anticipation of driving it for many more years. Following the repairs I was told by the mechanic that the frame was EXTREMELY rusted and that the entire frame would need to be replaced. There are large holes rusted through in many areas of the frame and a tremendous amount of rust over the entire frame. Rusted Pieces of the frame have fallen off. I fear for the safety of my family and me if I were to drive the vehicle at all. I have barely driven it since learning of the dangerous condition of the frame. I've limited any driving at all to my immediate area, and have driven very carefully and slowly, as I am extremely concerned that there might be a catastrophic failure of the frame while driving and I may be injured or killed, or worse....the vehicle might cause harm or death to another person. I am now basically without a vehicle and have been forced to rely on my daughter's car, leaving the family with only one vehicle. This is a major failure of the vehicle. I can provide photos and video at your request. Toyota must be held accountable for the failure of this frame. The vehicle is now useless. I expect Toyota to rectify this situation immediately. Please contact me as soon as possible. Thank you. [XXX] INFORMATION Redacted PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6).

- Newton, NJ, USA

The right rear control arm mount completely rusted away from the frame. Causing it to start fish-tailing out of control. Also there are other mounts that have rusted through. Like for instance, the gas tank strap mounted to the frame. There are also more areas of the frame that are rusting through. I'm just glad that I was the only one in the vehicle and going slow enough to not cause an accident. I then took it to an auto repair shop and they informed me that the frame on my vehicle has many problem areas of being rusted through. I have attached some photos of the problem areas taken from the repair shop.

- Sand Lake, MI, USA

2004 Toyota 4 runner frame is corroded so bad and dealer mechanic thinks it is a default of manufacturer and suggested I file a complaint with you. He said many Toyota 4 runners having same issue and it is a safety hazzard.

- Ingleside, IL, USA

My 4 runner only has 147,000 miles and is a great running vehicle but my frame is rotted badly. I have large holes throughout, the front crossmember under radiator with tow hooks has completely rusted off, and now I found where my rear lower drag link bolts to frame is about to come off. I have had to repair rusty brake lines multiple times. My rear axle carrier just sheds large flakes of rust. I love this truck but now it is almost too dangerous to drive and with all the inflation lately I cannot afford another vehicle.

- Kernersville, NC, USA

The frame of the vehicle has rusted so badly the Toyota Dealer I have taken to for diagnosis and repairs refuses to put the vehicle on their lift to inspect or work on the underside of the car for fear of the safety of their workers. This is not a new problem for Toyota because they have lost a civil suit for premature rusting of the frames on other truck models. I took my 4Runner to a frame repair shop and got an estimate. I don't have the funds to do the repair. If the repairs were not made I could continue to drive it until the frame breaks I was told. When the frame breaks it's indeterminable, how many individuals could be injured? My hope when the frame breaks I don't lose control so I won't be killed or severely injured and any others that could be involved in the accident don't get harmed either. There has been a class-action lawsuit initiated where my 4Runner would be included in this suit. Toyota needs to be held accountable for a poorly designed and manufactured frame. I demand Toyota replace/repair the frame on my 4Runner so that it can be safely driven to the end of life of the engine and transmission before persons are harmed from a frame failure. Inver Grove Toyota first informed me the frame had holes rusted in it on November 19, 2019. Then, on Dec 20, 2019, they informed me it was unsafe to lift. I can supply copies of 3 repair invoices where the dealer made note of the corroded frame.

- Hastings, MN, USA

Vehicle has a rust frame which causes a dangerous

- Plano, TX, USA

Frame rust discovered by state inspection mechanic, vehicle fails for frame members rusted through. May not be repairable.

- Yarmouth , ME, USA

My steering became very loose with a lot of movement in the steering wheel. The universal joint in the steering column shaft was bad. Upon further investigation, both lower control arms on the front wheels were rusted through, (from the inside out), with one of them bent because of the lack of metal support that rusted away, which caused my wheels to be misaligned and hard to control. Upon additional inspection, the frame has rusted out in multiple places which could allow it to break in half. (pictures of one portion of the frame are attached.) I have had the steering column and lower control arms replaced but multiple body and frame shops state the frame is rusted too much to repair. I know Toyota recalled several models for frame rust issues but have not included the 4Runner, which I cannot understand. This rust has been noticed for several years on my vehicle with attempts to keep it clean and rust free. However, the rusting process is occurring from the inside of the frame toward the outside, so you can't tell how bad it really is until you see the holes protruding through the frame. This model should be included in a class action suit requiring Toyota to compensate the owners for this defect and removing these models from service to avoid potential accidents and casualties caused by inferior iron products that were used in their manufacture.

- Lost Creek, KY, USA

I took my car in for repair. Check engine light and VSC track lights on with horrible sound beneath the car. The auto repair shop called me and said the frame and underbody of the car is so rusted it will break apart if I drive over a pothole. So rusted that there is nothing to be able to attach to under the car. I am original owner and had rust proofing applied to the car there when I bought it. They charged me nothing because there is nothing they can do, they can-??t even weld it it-??s nothing but rust.

- Annandale, VA, USA

Frame started excessive rusting before 2011 when the vehicle had very low miles on it. I reported it to Toyota National headquarters in 2016. They knew about it but since they didn't have to replace the frames they didn't care. They offered me $1000 towards a new car. I could not afford a new car. I have been battling the rust ever since. I spent $4000 in the past 2 years. I was driving with a broken front axle!! Recently the rust corroded my brake fluid lines causing the lines to fail all at once. Luckily I was leaving my driveway. I had no brakes and was headed for the road. I hit the emergency brake and stopped at the road. Brake fluid fell out all over my driveway. I had to spend $400 getting my driveway resealed and $300 for the new brake lines which was really cheap. I took the truck to Toyota to trade it in and they would only give me $1500 for the beautifully, well cared for truck with only 135000 miles on it because the frame was rusted. They replaced the frames on the Tundra and Tacoma, which were the same frames. They need to replace the frames on the 4Runners or compensate the owners like me. I am the original owner. I bought the dealers demo in 2005. I want the $10,000 they owe me. I am moving and I have to sell this truck, instead of waiting for Toyota to replace the frame, because it is unsafe to drive from NY to NC. I am very sad. Other than the rust this truck is fantastic. I feel like a good friend died! It hurts to let it go. I will have to sell it privately. I think $1500 from the dealer is criminal.

- East Patchogue, NY, USA

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 of $139 but that Toyota would not help with repair or replacement of the frame. There is no need to inspect the vehicle as I have multiple pictures illustrating the magnitude of the rust damage to the frame including several holes multiple inches in diameter in critical locations of the frame. I have attached several photos of the rust damage as well as photos of the body for reference to how well kept the vehicle is.

- Arnold, MO, USA