Body problems of the 2002 Toyota 4Runner - part 1

Frame rot.

Had vehicle inspected on oct. 1 ,2021 for road trip to north carolina from washington, DC. Was informed that my vehicle is unsafe by the automotive shop (name withheld) due to [rusting] frame front suspension components' threads rusted off on bolts that hold suspension, control arms, and shocks on both front and rear areas + body of vehicle located where shocks bolt to the body. I also had two other shops (names withheld) assess the state of the frame and suspension + and was told that the vehicle has maybe 1 year or so until the frame falls apart. Given I am the original owner, have gargage-kept my vehicle, have very low-mileage - 74,000 miles, and have maintained the vehicle immaculately and am aware of rusting problems with other Toyota [truck] frames, etc. This seems to be a defect in the manufacturing process. I know there have been recalls on Toyota's other trucks due to Toyota's failure to add [enough?] rust inhibitor/preventative to the molten steel when forming the frame for many models of their trucks.

Frame is excessively rusted. The recall that already exists for this issue only covers certain frames from japan made with this steel. However, the same frames were imported to America and a large percentage of 4runners were made with the same steel and didn’t receive a recall. Mine is one of them.

After having my 4 runner in for routine maintenance, my mechanic informed me that my frame was in bad condition and rusting through. Doubtful it has a year left and he advised me to junk it as fast as I can. 180;000 miles - so much for Toyota’s lasting a long time.

Frame and rear passenger control arm bracket, rotted out . Only there, 2 nd time this has happened, same spot but on my previous 2001 4runner.

Frame is showing excessive rust all over, a known problems with 4runners and Toyota trucks. Auto repair shop says vehicle probably has only 1 year of life left before unsafe and undrivable. Car has only 100000 miles on it, 1998 4runner we had made it to 250000 miles- unacceptable.

I recently had my vehicle in for service and to get new tires. While on the lift, the mechanic pointed out to me that the frame on the passenger's side is beginning to rust through. This is an obvious potential safety issue and as I have researched possible repairs, it appears that this is a very common problem for this year and model. This should be recalled.

Rust/rot damage to passenger side frame. Extends from middle cross member to rear cross member. Also significant rust damage to rear shock mounts. Failed inspection as a result. The rest of the car is in excellent condition and well maintained. Safety issue for my family.

Tl the contact owns a 2002 Toyota 4runner. The contact became aware that the subframe underneath the vehicle was severely rusted. The vehicle was taken to an independent mechanic and the contact was informed that the subframe needed to be replaced. The repair was still pending. Toyota of Lincoln park (1561 n fremont st, chicago, IL 60642) was contacted by phone and informed of the failure. The contact was informed that the dealer was unable to repair the vehicle. The manufacturer was not notified of the failure. The failure mileage was approximately 120,000. The VIN was not available.

2002 Toyota 4runner, original owner with only 110,900 original miles on it! vehicle has severe rust/rot damage to passenger and driver side frame. Extends from middle cross member to rear cross member. The rest of the car is in excellent condition and well maintained. Safety issue for my family. Repair will be necessary soon, as I'm starting to not feel safe driving long distances or at highway speeds (70+ mph). Thank you!.

Very excessive rusting and corrosion on the frame near where the leading arm attaches on the passenger side. Hole has developed very quickly, only in the span of a couple years. When going around left corner >15mph, a clunking noise can be heard from the problem area. Very occasionally a similar noise can be heard when going through right turns. Vehicle has spent most of its life in southern minnesota, although some time has been spent in south florida. Repair will be necessary soon, as I'm starting to not feel safe driving long distances or at highway speeds (70+ mph). Thank you, have a nice day.

Vehicle frame has corroded, fractured especially on passenger rear of vehicle. Many holes along frame. Was hearing loud thunking in rear of vehicle took it in for a visual inspection and found the issue.

We purchased a 4runner for our 18 year old daughter to drive thinking it would be safe, esp in mn. She was driving home from college (130 miles) and noticed it had a bad vibration, especially over 40 mph. It was very difficult to drive. We were out of town and when we got back, brought it to the shop, only to be told the frame was responded beyond repair (see photos). Not only does that scare me for my daughter, but she has been driving it a few years and had friends and other family members in the vehicle. The vehicle has relatively low miles for it's age and based on Toyotas reputation of longevity, we never expected this sort of issue. We're thankful she wasn't hurt, but are concerned about others driving a vehicle and not knowing it could literally break in half while driving down the road!.

At a stop light, went to drive heard load pop clank. Vehicle started shaking and driving funny. Looked under car and my control arm ( that stabilizes my axel ) mount rusted off. My entire under carriage is rusted out. The control arm shifted.

Premature rusted frame throughout, vehicle is garaged and well maintained 117,000 miles on my 2002 Toyota 4runner. Auto body specialist estimates $3k-$4k to restore, at least.

My 2002 Toyota 4 runner failed mass state inspection due to emergency brake not engaging. I immediately brought the vehicle to a local auto shop for repair. I was then notified by the shop that the entire frame was completely rotted & unsafe to drive. They refused to do any repair to the e-brake until the frame was repaired. I'm devastated that my well cared for vehicle , with only 130,000 miles is now unsafe to drive due to frame rot.

Tl the contact owns a 2002 Toyota 4runner. While the vehicle was undergoing routine service at an independent mechanic shop, the technician noticed that the frame was corroded through and caused the tailpipe to detach. The vehicle was not taken to a dealer. The vehicle was not repaired. The manufacturer was not made aware of the failure. The approximate failure mileage was 168,000.

Check engine light comes on so I take my 2002 4 runner to get it checked. I noticed it sounds like it might be a exhaust problem. Then I get the bad news . The frame experience excessive corrosion. My understanding is that there was some kind of recall on this matter a few years ago but I never received a notice . I purchased it used in 2003 so maybe the notice went to the first owner. I have been living at the same address since I owned it.

I have a 2002 4 runner and put almost $2,800. 00 in it last year for a new rear end, new tires, because I felt it still had a tremendous amount of life left in it, only to find out that the frame has 2 holes in it from excessive rust. The dealership I took it to informed me that they were currently in the process of replacing frames for 2003 - 2009 models. When I asked about the 2002 models, they stated that Toyota does not assume responsibility for the 4 runners. My question is "how do I find out if the 2002 frames were manufactured with the same materials that the 2003 models were made of?" I really wanted to hand this car down to my daughter. She needs a car and with the current situation of the frame, there is no way I can let her drive this in its current condition. Please help!!!.

My frame is suffering from premature and excessive rusting, as is commonly reported among other early to mid 2000's 4runner owners. The most severe area is the radiator supports. I am filing this complaint so it is registered among the many complaints received about this issue. I'd be happy to provide documentation if needed, but I'm pretty sure there have already been a lot of reports of this since there's now an investigation into the issue.

Frame deterioration.

The frame on my 4runner is completely rusting. Had to get it spot welded to pass inspection. This is a common problem on 3rd generation 4runners. Please help.

When taken to the local automotive shop they found the frame has rotted out in many parts of the frame. Cab frame mounts are also rotted. It will not pass inspection. The frame is ready to snap offf. Thank the lord the shop found this being three of my four kids ride in it everyday to school.

The contact owns a 2002 Toyota 4runner. While the vehicle was being serviced, the technician found severe corrosion on the passenger side. The contact stated that the frame would need to be replaced. The vehicle was not repaired. The manufacturer was not notified. The failure mileage was approximately 150,000.

Frame is perforated by rust where the rear control arm mount meets the frame rail.

My 2002 Toyota 4runner has a couple quarter sized rust hole on the rear right side of the frame. Located on the inside next to the exhaust muffler. The entire rest of the frame is in very good condition, it's weird to me that just this particular spot is completely rusted through, this is a huge safety hazard and I know Toyota should step up and do something about this. I read online most people have this same problem in the same exact spot. Seems like a defect in the frame. I'm hoping to have Toyota cover this incident. Thanks for reading. Brandon.

The frame of the vehicle is rotting out with rust. The 4runner has never been in snow and has been taken well care of and the frame is still eroding away with rust at an unnatural rate. This issue must be addressed for the sake of so many unaware owners!.

Tl- the contact owns a 2002 Toyota 4runner. The contact stated that while driving 35 mph, rear ended another vehicle. As an result, the air bags failed to deploy. The contact stated that no warning lights illuminated. As a result the contact sustained upper and lower back injuries that sustained medical attention. Police report was filed. The vehicle was taken to an independent mechanic for body repair and the air bag failure was not diagnosed. The manufacturer was not made aware of the failure. The failure mileage was unknown. Dr.

Frame cracked/rusted dealership reported that the frame (right rear) was cracked. . . . Car is unsafe to drive.

I visited a Toyota dealership for routine maintenance (oil change) and inspection of 4 wheel drive system. After the vehicle was raised on the lift, the service advisor asked me to join him and the shop mechanic in the service bay where I was shown that the frame / chassis of the vehicle has rusted the point where in their opinion it was no longer safe to operate. After close inspection, I had agreed with their assessment. An online search for a recall notice was performed, but none was found. Otherwise, this vehicle is in meticulous condition with no body damage or rust or any mechanical problems.

Vehicle was stationary. While replacing exhaust system components. Found what appeared to be minor rust on the passenger (right) side rear suspension mount. Further investigation uncovered a larger area of rust along the 3 welds on the inner frame rail. Cut / ground the metal back to good metal and am in the process of patching for my yearly maine vehicle inspection. Either Toyota has built an inferior frame or the newer chemicals being used to keep the roads clear in the winter to be the cause of this rust which could cause the rear suspension to fail at this point in the frame and cause a accident.

Fame deteriorating prematurely,skid plate that protects fuel tank showed signs of rust. After inspecting found rotting from inside out. When replacing in may of 2014,found that strap that holds fuel tank rusted completely away,two bolts from the rusted skid plate only thing holding fuel tank in place. Same conditions exist over entire frame,rust falls off in sheets when frame is tapped on with hammer. Brought my concerns to dealership in Jan. Of 2015 of rust issue, they informed me nothing would be done.

Tl-the contact owns a 2002 Toyota 4 runner. The contact stated that while driving at approximately 45 mph, the contact lost control of the vehicle. The contact had to apply force to the brake pedal in order for the vehicle to come to a complete stop. The vehicle was taken to an authorized dealer who diagnosed that the trailing arm was corodded and that the entire frame needed to be replaced. The vehicle was not repaired. The manufacturer was notified of the failure. The failure mileage was 119,000. The VIN was unavailable. Oo.

2002 Toyota 4 runner sr5, 98,000 miles. Always dealer serviced. This will be my last state nys inspection as I will be unable to have the truck inspected in 2015 due to body frame rot, need to incur costs to replace body frame. Truck is in excellent condition with the exception of frame rot. Have also replaced the bumper, the gas tank shield and have been told front oil pan shield needs replacing as dealer can not preform oil change, due to this problem. I have contacted Toyota waiting for a reply.

Extensive rust thru on drivers side of frame, rear suspension link rusted to the point where complete failure in coming soon. Last two feet of frame completely gone. Doubt it will pass another safety inspection without significant repair. Rear differential rusted to the point gear oil leaks. This is common on all 4 runners and should be recalled just like the tacomas.