Frame Rust problems of the 2002 Toyota 4Runner

Excessive rust on the frame. Have heard of other Toyotas from the same time that were recalled but not the 4runner even though it suffers the same issues.

The frame is rusted out and is making the vehicle unsafe to be on the road. This is a known problem with this frame, it's already been recalled on the Toyota tacoma and it's the same identical frame. It should have been recalled years ago. Just making a normal turn on a bend in the road makes it difficult to keep the vehicle under control.

I purchased the 2002 4runner in 2014. At that time, the 4runner only had 79,000 miles and had been cared for meticulously. I have taken the car in for routine service over the past 5 years. Upon taking the 4runner in due to a vibration and check of the differential, the mechanic called me in to look at the frame while it was up on the lift. Below in the attached photos, there is extensive rusting of the rear differential, axle and frame. The vehicle was stationary and the issue was found during routine maintenance. The rusted frame and differential have rendered this vehicle practically valueless and unsafe.

Right frame rail is very rusted to the point of non repair. Unable to repair suspension due to unable to remove bolts that hold suspension to frame.

I was doing an oil change and noticed that the frame was rusted very badly . I think that there should be a recall on this model 3rd gen 4runner (1999-2002)this is the same frame as the truck that was recalled ,so this should be included . If this frame breaks it will hurt or kill some one .

I have seen classi. Cars from the 60s with frames in better shape than my 4runner. The rear control arms brackets are close to detaching from the frame. Rust is eating the back half of my frame. The frame rails are completely rusted through and will soon need replacing. There are numerous bolts and hardware that can no longer be used due to rust. The fill plug on the rear differential has rusted away as well. The quality of this steel is absolutely horrible. Toyota should be ashamed of a vehicle that has problems like this. I have never seen rust this bad on a frame before.

First, the motor blew for no reason at 152,000 miles. I rebuilt the car and had a new motor put in. I was not aware of the rusting frame issue, however, after driving the vehicle with a lovely new rebuilt motor for about one year, the frame rotted beyond repair causing the power steering to go out. I don't drive much, so there was no excessive exposure to salt. The car was parked in my driveway. It was an exceptionally cold day. I started the vehicle and found the power steering fluid had frozen and lost all the fluid as a result of the steering rack being rusted and weakened. The repair shop told me that the frame and rocker panels are severely compromised too badly to bother fixing the steering rack. The car is not safe to drive.

Excessive rust on frame. Rusting from the inside out, on passenger side near muffler, by rear suspension mounts. Rusted all the way through on the inside of the frame. Likely rusted in other parts that are not visible.

My 2002 Toyota 4runner has excessive rust on the frame to the point that it has been deemed by my local Toyota dealership as "unsafe to drive. " it only has 180,000 miles on it, the rust should not be this extensive.

Rear axel is rusted off the frame, and rotting, mechanic says it's unsafe to drive.

Leaving work Friday of labor day weekend 2018 I noticed the smell of gas. My CO-worker also looked, and observed a puddle of gasoline under the car. Since the dealer was close, I took the risk to drive it the dealer. The dealer is heritage Toyota in baltimore maryland. The car has only 91000 miles on it. The entire bottom of the car is rusted out. This is what caused the fuel leak. The frame is also rusted out to the point of not being safe anymore. My complaints are these: 1. The underside of the car completely rusted out. 2. Other Toyota trucks of the same year are having their frames replaced by Toyota. 3. My Toyota was serviced with me letting the dealer do "anything it needs". I estimate spending about $15,000 at this dealer. Never once was I told there was a rust problem. With mounting repaired costs, I took it to another mechanic who immediately recommended that I take the car to the dealer for assessment. Never did the Toyota dealer warn me about the rust. 4. Toyota was completely uninterested in helping. I did file a complaint #1808271490.

Frame rust on the inside portion for the frame. 33" hole rusted through completely on passenger side. Rust continues about 80% of the way through the rear lower control arm mount. Driver's side has a similar amount of severe rust that has weakened the structural integrity of the frame to the point where it is no longer safe to drive. Should the CO troll arm mount finish rusting through, the axle will no longer be attached to the frame on that side. There is noticble flex and sound associated with the frame rot. It is only a matter of time before the control arm mount disconnects completely, or the frame buckles.

Frame is completly rusted out.

This is yet another costumer of the 4runner 3rd generation complaining about the frame rusting out. There needs to be responsability for the bad frames on this year 4runner. My frame has holes in the rear control arm attachment area and more rust all throughout entire frame. I'm doing all I can to keep my frame from getting any more rust on it and keeping it safe to be on the road. I strongly believe Toyota should also have a frame recall for the 4runner like it did for the tundra tacoma and sequoia frames.

"takata recall" frame rusted out from the inside out. Looking at on frame it was at least 1. 5 inches of dirt and small rock from maine roads and than when rained it was just mud the bad spot is on the passenger side d by torsion bar no way to drain. Also rear end differential gear cover rusted out on other vehicles you replaced just the cover on the 4runner I was told to replace the rear end price just for the rear end was $2500 than labor.

I have owned my 2002 4runner since I bought it new in 2002. Around 8,500 miles a year, and somehow my frame is completely rusted out. This is not normal, and now it won't pass inspection and is unsafe to drive. Toyota bought the frames from a third party in japan which did not coat these frames properly. We undercoated the car for 5 years after buying it, and yet rust started showing up around 2009. We have taken care of the car, everything except the frame is perfect and clean. Toyota is knowingly letting 3rd generation 4runners drivers drive their cars even when they're unsafe. They need to institute a buyback or frame replacement program. We don't know what to do now, because we can't drive or sell the vehicle, yet everything runs perfectly.

(ak no dealer info) tl the contact owns a 2002 Toyota 4runner. The contact noticed that the main frame was rusting on the vehicle. The vehicle was taken to an independent mechanic (mavis tires), but was not repaired. The manufacturer was not notified of the failure. The approximate failure mileage was 209,000.

Frame rust. The dealership determined the "frame is rotted-safety issue-will not pass inspection". This 4runner has only been exposed to areas of mild south east pennsylvania winters and the undercarriage was washed regularly after every snow and road-salting event. 4runner is trash after only 12 winters. 4runner was in storage for 04/05 winter and there was no snow in 15/16.

My 2002 4runner's frame is rusted through in many places. This is very unsafe and Toyota should fix this problem. They have yet to recall the 4runners but, have recalled the tacoma and sequoia. I do not have the money to do this repair. I am buried in debt from a heart transplant and this is just unacceptable. I think people will die from this problem. Please respond so I have some information please. Thanks, robert matteo 614-581-7904 columbus, ohio.

Frame is badly rusted out. Vehicle only has 80,000 miles.

The frame of this 4runner has been experiencing excessive rust since the time I got it used from a dealer. Once their undercoating wore off, my mechanic replaced rusted up brake lines back about 9 years ago. He said it was because the frame was very rusty and they did a new rust treatment. For the past few years I have been battling issues related to the frame. A plate was put in to strengthen an area. It only has 164k on it, I rebuilt the transmission at 125k, and the body is in good shape. Just that the rust is spreading everywhere underneath. We tried to get it addressed in the previous Toyota frame recall but it was not for this age for whatever reason. Every repair has been more difficult due to rusting bolts, mufflers rusting early, brake lines busting due to rust, the tow hitch rusted through. Now there is a gaping hole in the rear side of the frame supporting the cab. After being under the car trying to scrape rust off, and to put some rust restore/protection, I saw the new hole and got fed up. So I see you are now investigating this year 4runner to add to their recall. Please. . . Do! something serious could happen while driving it and it will just stay mostly parked until this is resolved. Brake failure when my son was driving was already scary enough. Thank you.

Frame is rusted through on right side from middle of the frame to just over the rear axel. There are large holes and rusted slots that are over 10 inches long damage starts before the rear suspenshion support and continues to the other side and the side where the rust has caused holes and long slots the whole frame can be squeezed easily with your hand.

Vehicle has 188,400 miles, runs flawlessly. Bought 2005, 45k miles,Toyota dealer certified used SUV. Rotted thru rear transfer case 3 yrs ago, replaced from a wreck. Severe progressive entire frame rust/rot noted in yearly PA inspections, now cant pass inspection & pillars almost rotted thru. . Unsafe to drive. Extremely disappointed cant pull trailer sailboat & m'cycles, now sits in driveway useless.

Hello. I purchased a 2002 Toyota 4runner limited edition last fall in pennsylvania. The car had passed the pennsylvania state inspection with passed validated inspection tags in the front window. I took the car to my mechanic, welder and beechmont Toyota (cincinnati OH) and the consensus is the car needs the car frame replaced. The car frame has rust holes and is rusted along with a rusted undercarriage. The integrity of the car is compromised, because the car frame has rusted holes in it, criteria that should not have passed PA state inspection. It does not have a safe car frame. I was sold a vehicle that passed PA state inspection and the car had holes in the rusted car frame. The sales guy who sold me the car, said that the car had passed state inspection in which the sticker in the windshield shows. I researched the state inspection criteria and I think it is 5a and 5iii that reference checking the car frame. Pendot did not take any responsibility for their failure of approving the state inspection. I asked for my money back ($6,200) from the car salesman plus I had to pay about $500 ohio tax and was told that it had passed pennsylvania state inspection and they would not refund my money. This car has a rusted damaged frame with holes and needs to be off the road as it's dangerous. I am asking for my money back, and I'll return the vehicle as it should not have passed pennsylvania state inspection. Thank you.

Frame rusted under 4 runner and on bumper told by person working on sway bar links. Stated excessive rust on frame and rear axle.

Frame has excessive rust and has holes in parts of it. The rest of the body and interior are in great condition. Engine runs well and there are otherwise no major mechanical issues. Upon having a minor repair done, inspection showed that the vehicle was unsafe to drive with the frame in that condition as it is about to crack in half. This seems to be prematurely failing compared to the rest of the vehicle.

Tl-the contact owns a 2002 Toyota 4runner. The contact inspected the vehicle and discovered that the entire rear end of the frame completely rusted. In addition, the rack and pinion was faulty and replaced by an independent mechanic. The manufacturer was notified of the failure. The approximate failrue mileage was 120,000. Js.

There is excessive rust on the frame rails which support the body of the vehicle thus weakening the critical supportive components. This creates a possible dangerous situation which may go unnoticed until failure occurs. This has been a common problem with other Toyota vehicles and should be addressed for the 4runners.

Frame rusted out, similar to tacoma pick up trucks recall. Additionally climate control heating, cooling, fan defective, power antenna in-operable.

Frame rusted through. There is a hole in frame because of rust.

(there was no category offered for frame). During a recent automotive service for brakes on 9-26-13 for my 2002 Toyota 4runner, I was notified of a rust perforation in the frame body near a rear support mount for the axle making it unsafe for operation. This is a situation where rust forms in the interior of the frame and works its way out destroying the structural integrity of the vehicle. It seems the service technician used to work at a Toyota dealership and knew exactly where to look from his prior experience with other 4runner failures. The Toyota dealer informed that this would not be covered. My ’02 4runner is from the same generation (3rd) and of similar design to the tacoma that was recalled for this the dealer instructed me to contact the torrance, CA Toyota customer service as his dealership would be unable to assist in anyway. It was clear they had encountered this before. Through discussion with Toyota CA they have no intention of providing any means of relief for a known and well documented safety problem. One rep did comment that the tundra and sequoia had been recently added to the recall but the 4runner was “not yet” on the recall list. It seems Toyota views the products to be different due to the body style differences or us vs japanese built products. They also clearly have no intention to escalate internally. I was instructed to file a complaint with NHTSA and ntsb. Research on line shows that there is a very widespread issue that Toyota is clearly choosing to ignore. Web information suggests that cold climate and the axle bracket in close proximity to the exhaust, are primary factors. How can you recall one model for a rusted frame due to safety but not another? personal photos available. Huge numbers of photos and reports available online - search " rusted frame 4runner" or similar.

Rusted through frame on the rear passenger side where axle support connects to frame. Measures approx 2. 5 feet. Rear end feels loose when navigating turns.

Takata recall. I have a rusty frame that needs to be addressed for safety reasons I was driving on the highway at 55 mph frame cracked and I almost died because of it Toyotas have shitty frame that should be recalled.

Excessive rust on frame since 2008. Toyota refused to address after filing formal complaint. I believe like trucks of same year that had frames replaced, 4 runners should be included.