Body problems of the 2003 Toyota 4Runner - part 1

Toyota has had issues with their frames rusting out and the 4th generation 4runner is not exempt from this issue. My 2003 is requiring extensive work to keep it on the road safely due to frame rust. A recall to replace frames should be in place.

Severe frame rust, there was a recall for tacomas but 4runners have the issue just as bad.

Vehicle frame has rusted through and has holes affecting structural condition.

Extensive rust through out frame, resulting in holes in structural members. Leaving frame in a weak and vulnerable state.

Excessive frame rust causing difficulty to keep vehicle on the road. No warning lamps, I noticed the rust starting years ago, now the rust is so bad that the frame is rusted through causing difficulty steering and loud crunch noises. I contacted Toyota consumer affairs explaining the rust concern and asked if I needed to take the vehicle to a dealership for inspection, they said it wasn’t necessary (sounds like they don’t want to admit the existence of a possible manufacturing defect). The vehicle is available for inspection. I feel like I would be doing a disservice to society if I continue to drive this vehicle on public roads due to the danger of injuring a pedestrian or another motorist.

So much rust has developed the frame is literally giving out. Toyota admitted to a rust issue- it’s now a safety issue with this generation of 4runner. They did a recall on the same frame for tacoma but not 4runner.

The frame of the car has been rusting at a significant rate in the last 4 years. Mechanic identified major rust issues that would make the vehicle not safe in case of an accident.

The frame on my 4runner is rusting through in multiple locations. The rear of the frame has already failed and a trailer I was pulling dragged on the road heavily as it failed. Definitely at risk of caving in long before the engine or transmitoo fails.

I have two 2003 Toyotas, a tundra and 4runner. The 4runners frame is rusting out everywhere including the welds. My mechanic said it was getting to the point that it’s dangerous to drive and if it was in a wreck the frame would likely fail under the stress. My tundra frame from the same year is immaculate. I believe the are similar frames. This is obviously a defect in the production based on my readings and is very common. The investigation was opened in 2018 and its now 2022, when will this get addressed!.

The frame of the vehicle is rusted to the point my fist can fit through a hole in the frame.

The frame on the vehicle is rusting out. If not repaired, serious injury could occur if the frame breaks. A compromised frame could cause serious injury if an accident occurs. The driver side main frame has a gaping hole on the inside and another hole forming underneath that is in close proximity to the larger hole. The entire back cross bar member supporting the bumper is rusting out as well as the front cross bar member. The vehicle was inspected in July 2020 and the dealership said the frame was ok and had plenty of life left in it. After getting a muffler installed at a local independent shop in October 2021, the hole grabbed the attention of the technician. After inspecting, rusty flakes kept falling away.

Extreme frame rust. The vehicle has extreme frame rust and Toyota should be held accountable for poor quality frame material. I have heard tons of stories of other peoples steering components snapping due to rust and frame damage.

Vehicle frame and suspension components are completely rusting out. Having issues with the corroded steering column lower shaft not allowing the vehicle to turn properly.

The frame is rusted very bad and it’s a major safety issue for this type of vehicle I don’t know when it’s going to fall apart. I am sure I am not the only one to have this problem.

Really bad frame rust, holes in frame, engine mounts. . . . Cracked dash board. All problems shared by many 2003 4runner owners too. I'll take more photos. . Thanks for your attention.

Due to severe rust underneath the vehicle, there have been a few issues that have made the vehicle very unsafe to drive. Last week, both of my rear brake lines were completely done and leaking brake fluid leaving me with no brakes. This was due to rust and corrosion that had eaten the metal lines away. The radiator mounts are corroding, as well as the skid plate for my fuel tank and a few spots on my frame near the rear. I was not aware of the rust as I just got the vehicle a few weeks ago. I was driving in traffic when my brake light came on and I noticed my brakes didn't seem to be very effective and they eventually got the point where they were not working or slowing the vehicle at all. Once I took it to the shop and they put it on the lift, the mechanics pointed out just how bad the rust was.

Car inspection at a service center revealed advanced rusting of the frame. I was told this could be dangerous.

The frame is completely rusted through and soon will be unable to support the steering, engine or drive train. The problem was confirmed to me by an independent service center that I have used for 10 years and I trust.

At the end of June 2021, while driving I experienced a loud clunk and grinding noise, with reduced control of steering and brakes on my 4runner. I took the 4runner to a goodyear automotive service center on woodward avenue in royal oak, michigan, who told me that the vehicle was not driveable due to severe rust damage of the frame that resulted in a broken sway bar. I thought I should take it to the closest Toyota dealership in troy, michigan for advice and they responded that the vehicle was beyond repair and that a new frame would cost around $20,000. I could not leave my car there, and risked driving it home, where it has been parked ever since.

The frame has rusted almost completely through near the front upper and lower control arms near the cross member there. The passenger side is so bad the welder I took it too sad he couldn’t repair it without doing the crossmember section and all. The driver side is not at bad but doesn’t look to hot. The crossmember where the radiator sits is also starting to completely rot away.

I heard a loud noise (scraping-dragging) from the bottom of the engine area while driving on the highway this was a very dangerous and scary incident pulled over and my fiancé checked under the engine a very large metal piece was dragging the road I did not hit a bump or anything. A body shop mechanic informed me that the chasis of the 4 runner was in extremely bad condition the 4runner will not pass inspection because of this condition I respectfully request help in this matter.

Three mechanics said the frame was rusted with holes and is unsafe to drive. The vehicle is not inspectable, so had to have mechanic weld steele on frame to be able to pass inspection.

Frame rusted to the point the shop won’t fix the brakes and allow me to drive the car. The brake line rusted through since it was attached to the frame and when repairing the brakes they found the frame rusted too bad and coming apart. Looking online this seems to be a common problem with this year Toyota 4runner.

I heard there's an investigation on these frames so mine is rotting away.

In reference to NHTSA action number: dp18002. My mechanic informed me that my 2003 4runner is starting to experience excessive corrosion on the frame. He informed me that this is common with this model. I contacted a body shop to inquire about possible solutions. I was informed that they get inquiries about the 2003 4runner often yet they do not like working on them as the frame is constructed in such a way that it is difficult to address the corrosion issues. I'm reporting this to help facilitate the ongoing investigation and to inquire about any progress being made on the investigation.

I own a 2003 Toyota 4runner with very low mileage for its age. It has been garage kept for most of its life. I was experiencing difficulty steering, and when I took the car to a mechanic, it was determined that the frame was prematurely rusted and rotted to a dangerous level putting my life at risk while driving it.

The contact owns a 2003 4runner. The contact stated that while the vehicle was being repaired, he was informed that the undercarriage and subframe of the vehicle was extremely rusted. The vehicle had not been taken to a dealer or independent mechanic to be inspected. The manufacturer was not made aware of the failure. The approximate failure mileage was 139,000.

The frame of my car is corroding at an alarming rate and even after treatment it continues to rust to the point where my car is not safe to drive.

The whole under side of the vehicle is rusted. It can't even be driven. My brake line busted the other day (with my kids in the car) and caused me to lose the use of my brakes. We are okay, and the mechanic was able to repair the brake line. But my mechanic was able to stick a pen through the frame. He said with this excessive rust, I should file a claim. After searching online, it seems that there have been recalls on other models of Toyota because of rust. Hoping you can investigate and make this right. Thank you!.

The frame on my vehicle is rusting prematurely. It's doing this on many other 4runners and other Toyota trucks.

Rear driver side control arm broke off at the frame after striking pothole at highway speed. After the failure the vehicle was very hard to control and almost led to a rollover. The vehicle was unable to be driven and had to be towed. Toyota recalled tundra's, tacoma's, and sequoia's for frame replacement so it is a known problem. Will Toyota be held liable for accidents resulting from premature frame failure? by recalling the other models they obviously acknowledged it was a problem and 4runners share the same platform as the tacoma so why were they not included?.

The frame of my 4runner is so so rusted that my mechanic put his finger through a piece of the frame it is so unsafe for mr and my grand children and everyone else on the road that it literally makes me sick. It'd the only vehicle I have so I have no choice but to drive it. It terrifying. It is available to inspect at anytime. I just bought this vehicle less than a year ago from a dealership and it so sad that they wld sell it to anyone knowing the frame was rusted its criminal in my opinion. It is for sure a safety hazard to everyone. I hope that this investigation proves to help get all of these 4runners off the road. So that a preventable tragedy doesn't happen.

Excessive rust / rot on the frame like the tacoma, sequoia, and tundra. Toyota hasnt put anything out for the 4runners. Found damage 31oct2020.

Frame is almost completely rusted out even thought the rest of the car is in good shape. I am afraid to let my son even drive the car. I read about the girl that died from the axle coming loose and part of the frame that holds the axle is in horrible shape. Toyota should be required to add these vehicles to the frame recall. . .

I purchased this 2003 Toyota 4runner in 2018 under what I assumed was prime condition, for a vehicle that spent the majority of its life in nebraska/kansas before I moved to texas in 2021. At 87,400 miles at the time of purchase, the vehicle had no visible damage to the exterior besides a few paint chips, some minor hail damage and scratches, and some easily fixed surface rust in the paint on the tailgate. The previous owner had driven it leisurely and had kept the miles low after 15 years. The car has had some mechanical issues, but nothing out of the ordinary outside of some regular maintenance over the first few years. Being close to 100,000 miles, the timing belt and pump was replaced around 98,000 miles. Other issues have been fixed periodically, please reference the attached files. After joining a Toyota 4runner 4th generation facebook group and seeing a post about another's issues with rust damage in October 2020, I decided to take a look at my own frame. I then inspected my own vehicle, and found significant frame rot damage. It is extensive, with significant rust to the frame, with large holes and soft patches that question the integrity of the frame and the safety of the vehicle on the road. Every time I hit a small bump or pothole, I fear the frame will crack and I will lose control as others have. I have not sought out professional repairs due to the extensive cost, and am awaiting the outcome of a current class action lawsuit by the bell legal group. The 4th generation Toyota 4runner (2003-2009) is built on the exact same frame as the Toyota tacoma of that era, yet while the tacoma was recalled for frame rot, the 4runner was not included, which I believe to be a gross oversight in previous legal proceedings. The 2003-2009 Toyota 4runner is a reliable vehicle, but poses significant frame rot issues much earlier than should be expected.