Three problems related to front suspension control arm have been reported for the 1996 Toyota 4Runner. The most recently reported issues are listed below.
Known documented issues with Toyota 4runner frame rot. This particular vehicle the control arm support brackets are showing signs of rust through with holes appearing in the brackets. This is documented with photos! the vehicle was purchased new by my father in 96, always garage kept ,in 2006 I bought the vehicle from him and also is kept in a dry garage not sitting out over moist soil. The 4runner has never been in a accident. I am a certified mechanic who performs safety inspections as I work for engineering university. It came to my attention when I was hearing and reading stories of these 3rd generation 4runners have stability problems directly related to the rusted out frame support brackets that hold the control arms in place for the rear axle. This is a main frame component , if the support bracket break free it allows the axle to wander around as it's not being held in place, causing loss of steering stability, it is a road hazard that is eventually going to kill people . I have a 95 blazer that was purchased six months before the 4runner and I still have it! the body on the blazer is literally rusted everywhere however,the integrity of the frame is still solid but the frame is rusted badly ! conversely, the body on the 4runner is excellent especially for the year, having a rusted out body is a appearance issue not a safety related issue as in the 3rd generation Toyota 4runner that reside in the upper midwest. Toyota has a a buy back program with tundra pickups that have frames that are safety hazards. I feel these 4runners are no different than the tundras, Toyota should have the frames either replaced or buy the vehicle back! I took great care of this 4runner it looks great ,however I can not sell it due to the possibility of the control arm breaking free from the frame caused by inside frame rot.
As I was making a right hand turn from a stop, the vehicle became severely poor handling. Upon inspection, it was realized that the mounting flange for the right rear control arm and frame had rusted through and the control arm was no longer connected to the frame.
The vehicle right rear veered to the right because lower control arm detached (broke) from frame (strut rod fastened to the frame). I lost control of vehicle but regained, narrowly missing a little girl on her bike. Toyota has had recalls on tacoma, tundra, and some sienna for prematurely rusted and broken frames. I called Toyota in local town and they said my VIN number has had no recall. To my research, the 4-runner has the same frame and build as the tacoma with numerous recalls. Mechanic stated the break should never have happened. I have kept this vehicle within all manufacturer's suggested repairs and maintenance. I trusted Toyota as a vehicle that was safe and dependable.