Frame Rust problems of the 2004 Toyota 4Runner - part 1

The frame is rusted through on this 4runner. Same frame as the tacomas that were recalled and I’m wondering why Toyota wouldn’t recall the same exact frame with major rust issues on a different platform. This truck is not abused so it’s very frustrating to see it falling apart at the frame when everything else is intact and solid. The rot on this frame is inevitable. I’m going to be very upset if I have to pay out of my own pocket for something that should be 100% covered under recall. This is a huge safety hazard and could lead to serious injury or death.

Our 2004 Toyota forerunner with v6 engine was purchased as a used vehicle in 2019 with 106,000 miles on it. Since then, it has developed more and more areas of rust on the frame despite our efforts to mitigate this issue. We have had to repair the frame, suspension, brakes, and wheel bearings. We continuously inspect the undercarriage and continue to discover more and more areas of significant rust/deterioration despite efforts to clean, treat (with paint, rust inhibitors, welding repairs). We are concerned that this deterioration will soon result in a catastrophic failure and possible accident resulting in property damage, injury, or death.

I have another 4 runner with a heavily rusted frame. I am very concerned that a unseen failure can occur while towing a 4300 pound camer or while driving on rough roads. I'm not only concerned for my wife and I but also for our grandkids that visit us monthly. Here is the actual failure. My wife came in last Thursday and asked me what is that car part that fell off? I went out to check and found the right body mount laying there. The bolt that holds it had rotted in two between the upper and lower rubber pieces. The bolt and nut on the bottom looks good so there was no indication of a imminent failure. I'm concerned that other more serious failures can occur.

Excessive frame rust causing front right front body mount to detach from the frame, passenger frame rail has disintegrated between crossmembers. The 4runner has 170000 miles on it with no body rust.

Many signs of premature rust on the frame with several holes. The truck only has 124k miles and should not be in this state. Toyota has to recall these frames just like they do from other trucks manufactured during the very same years.

Frame rusts too easily. Coating was not good enough from factory. Tacoma's with same frame were recalled.

The frame has rust and has a hole. It is unsafe to drive and will need to be addressed very soon. There was no specific incident. I recently bought this car. I don't know when it happened.

The structural frame of the vehicle is rusted out. Holes, large areas of the frame has rusted out. The frame is structurally compromised. Just noted on 10/19/20. Vehicle was in less than a year earlier with no sign of the damage.

Severe frame rust on 2004 4runner sr5 sport. Suspension rust, steering components rust. Holes in vehicle frame due to rust. I went to two mechanics that told me that this rust was beyond reasonable for normal rust on frame, they both stated it may become dangerous and to contact Toyota directly. The vehicle is becoming dangerous to drive due to possibly of failing components and or frame.

Frame has sever rust-through and corrosion on the passenger side in front of the rear trailing link mount and behind the front control arm mount. Vehicle is driven in an environment where road salt is used in the winter, but this is excessive compared to other older vehicles. Vehicle is washed regularly in the winter.

I recently bought a used 2004 4runner and when I inspected the frame there was rust everywhere. Not only surface rust but actual holes in the frame from it. Also the steering assembly is completely rusted out. I'm not the only 4runner owner who has experienced these issues. If you do a quick online search for �4runner frame� there are many results detailing this issue. As I use this vehicle for commuting to and from work I am concerned about its structural integrity. It only has 70000 miles on it and it's completely unacceptable that Toyota has not issued a recall for this problem as they did with other models (tacoma, tundra, sequoia).

Our 2004 4runner was inspected yesterday (virginia requires annual inspections), and failed due to rust holes in the frame. We have a photo of the holes. This seems odd to us, because the body is rust free and we live in a southern state where there is not a lot of road salt. Virginia does not allow any modifications to frames. I'm not sure whether this can be repaired. We've maintained the car in tip top shape and are very disappointed in Toyota. The car is registered in my wife's name, [xxx]. Redacted to protect personally identifiable information pursuant to the freedom of information act (foia), 5 u. S. C. 552(b)(6).

While driving the vehicle and after turning onto a state highway it suddenly swerved badly and the rear end began swaying back and forth making it uncontrollable. I stopped the car immediately. It was discovered that the frame had rusted so badly it became separated from the rear axle. I had to tow it home on a flatbed trailer.

Severe rust on the frame.

Frame is rusting. There are 2 big holes.

Frame is completely rusted out. The engine and transmission are strong but the frame is the weak link to this Toyota. This vehicle will not pass inspection and will need to be scrapped.

My 2004 4runner frame has a major rust problem. It has holes all over and some parts are breaking down due to rust. I took it to a Toyota dealer. They told me that they cannot do anything. They didn't advice for replacement as the cost, they say, could be around $15,000. I didn't want to get rid of the car as it has only 74k miles and the body, interior and engine are in perfect conditions, almost like new.

Car frame is completely rusted. Nothing is repairable anymore. Rear suspension and break lines effected by rust and broken! rear suspension can't be fixed due to rust broke connection to frame. This is not acceptable , specially since there is a recall for the same frame model on tundra, tacoma and sequioa at Toyota!.

Frame is severely rusting. Holes present which had to be patched numerous times for it to pass inspection. If something is not done soon, I will be forced to get rid of the vehicle because of safety concerns and it not being able to pass PA inspection. This has to be addressed now. For years, Toyota dealerships have been supposedly taking pictures and sending them to Toyota. They know it is a problem and nothing is being done about it!.

Vehicle frame has rusted completely through in certain areas - structure and safety is compromised . . . . Normal driving & care environment but appears frame has accelerated deterioration, while all other areas (body panels, all other components) are in excellent condition - seeing this is a known Toyota issue on same models and similar models of same production years.

Frame has rust problems. I spent thousands of dollars to keep the 4 runner functioning safely and now it is all to waste because the frame that the truck sits on is rusting out and is no longer safe to drive. Toyota must take accountability and include the '04 4runner on the frame recall. My 4runner is in excellent condition, except for the frame. Toyota dealership manager did not want to work on it and even admitted that it's a very common problem.

Severe rust on frame and suspension attachment points. Rust is not superficial but rusting from inside of frame tubes.

Toyota 4 runner. Consumer writes in regards to frame rusting. Consumer states that they noticed that the frame of the vehicle was rusting from the inside. The manufacturer was notified.

2004 Toyota 4runner with 110k miles with rusted frame. The car is otherwise in perfect shape and well maintained. The frame rust makes the vehicle unsafe to drive all other Toyota models with the same issue with frames from the same factory were recalled. The 4 runner was not addressed.

Frame has rusted through in at least three areas. In addition, parts of the frame I can pull off by hand. The front crossmember is 80% what it used to be due to parts falling off caused by rust.

Tl the contact owns a 2004 Toyota 4runner. While the vehicle was undergoing routine maintenance, the contact was informed that the passenger side subframe had excessive rust and there were holes in the subframe. Prestige Toyota of ramsey (located at 1096 NJ-17, ramsey, NJ 07446, (844) 838-7075) informed the contact that the subframe needed to be replaced and the vehicle was unsafe to drive. The vehicle was not repaired. The manufacturer was not contacted. The approximate failure mileage was 140,000.

Tl the contact owns a 2004 Toyota 4runner. While the vehicle was undergoing routine maintenance by an independent mechanic, it was discovered that the subframe was rusted and corroded. The mechanic stated that the vehicle was unsafe to drive. The vehicle was not diagnosed or repaired. The manufacturer was notified of the failure and did not assist. The local dealer was not notified. The failure mileage was 160,095. The VIN was unknown.

Frame has rusted through, leaving several holes, some very large, presenting a significant safety hazard.

I own a 2004 Toyota 4runner with significant rust on the frame that has nearly rusted through in some areas. Through my research I determined that this has been an ongoing issue for many Toyota vehicles close to the 2004 model year. Apparently the frame was not properly coated and rust has grown on my vehicle as well as many others at a much faster rate than is typically expected. I am worried about the safety of my vehicle as a result.

Takata recall, the radiator mount and frame supports are rusted out, also the rear shock and air suspension mounts are rusted out. Vehicle was in motion when shock mount broke.

Frame is rusted so bad it is about to break in half. Mechanic said he has never seen anything like this before. Frame should hold up better than this. Afraid to put frame up on lift to rotate tires because thought it would break in half. Frame is rotting before our eyes. Vehicle still runs good. It is a shame the frame is wearing out before the vehicle does. Vehicle is drove everyday. Hopefully frame will not give way while drive on the road.

I have 2004 Toyota 4runner v6 4. 0 sr5. Milage 130. 000. The frame has a lot of rust. Especially the passenger side thru whole that side. The front radiator mounts are also corroded. Back side of the vehicle frame is also corroded. Basically whole frame is very rusty. If I touch the frame the pieces start to fall down. Everything is ok with vehicle only the frame is very rusty. I do not know how long I can drive like this. Hopefully more people will get involved and Toyota will solve that issue. 4runner is a great vehicle. I would like to drive it at least 5 more years. Unfortunately I think I will not be able to drive it because of rusty frame. Driving will no longer be safe. I hope more 4runners 4th generation owners will complain and Toyota will replace the frames.

Truck frame rusted through.

Frame is severely rusted with large holes throughout. These vehicles are no longer safe to drive. Toyota has had issues with rusted frames with many trucks and apparently the 4runners is no exception.

I started hearing a noise like friction coming from under the car and feeling it through the steering while driving. It would come and go and within a week the car was undrivable. Just after exiting the interstate and on a side road, my brakes went out and there was an incredibly loud metal on metal grinding noise. I pulled over immediately and had the car taken on a rollback to my mechanic. When he put it on the lift he said that the frame was so rusted that it was undriveable. Most everything that was atteched to the frame was coming loose, like the brake calipers, cover over the gas tank, axles, etc. The frame is so rusted that he could literally put his hand through it. This could have been a very bad outcome if I had still been on the highway when it all broke loose.