Manifold/header/muffler/tail Pipe Problems of Toyota 4Runner

Toyota 4Runner owners have reported 19 problems related to manifold/header/muffler/tail pipe (under the engine and engine cooling category). The most recently reported issues are listed below. Also please check out the statistics and reliability analysis of Toyota 4Runner based on all problems reported for the 4Runner.

1 Manifold/header/muffler/tail Pipe problem of the 2005 Toyota 4Runner

Failure Date: 07/11/2019

Severe corrosion of frame at the rear body mount location. The body of the vehicle is no longer secured to the frame at this location due to the severe rust. Significant rust also on the front cross frame member which has the tow mounts rendering them useless and unsafe. Cracked exhaust manifold causing excessive engine noise and exhaust fumes. This is a time consuming and costly repair.

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2 Manifold/header/muffler/tail Pipe problem of the 2008 Toyota 4Runner

Failure Date: 02/14/2019

Exhaust manifold cracking on Toyota v8 4. 7 engine allowing exhaust fumes into the cabin and causing dizziness. When doing my research ive seen pages and pages of this issue known to Toyota about the 4. 7 engine that is used in a number of there models from Lexus to the tundra pick lines and anything that uses the 4. 7 engine. This is deadly being in the midwest and you have your windows up and heat on in the winter or summer with ac on. Thank you for your time.

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3 Manifold/header/muffler/tail Pipe problem of the 2008 Toyota 4Runner

Failure Date: 05/31/2018

Whenever I accelerate on the uphill or high accelerate then odor became really horrible, harsh smell, smell like tnt firework, either matches then egg rotten. I suspect the exhaust system seem faulty. I went multiple auto shop they mention it could be related to exhaust manifold but when I described that the odor came out from outside not interior air vent then they started to re-check my exhaust and said I am all good to drive as well, its "ok". The odor is frustrating, annoying. And the steering, I don't know how did my cv axle is leaking, I hopefully it will not break out when I'm driving to other state.

4 Manifold/header/muffler/tail Pipe problem of the 2005 Toyota 4Runner

Failure Date: 08/08/2017

Tl the contact owns a 2005 Toyota 4runner. While driving at any speed, the check engine indicator illuminated and remained lit. The vehicle was taken to ackerman Toyota (314-351-3000, located at 2020 hampton Ave, saint louis, mo 63139) where it was diagnosed that the air switching valves needed to be replaced. The vehicle was taken to an independent mechanic where the exhaust manifold and the air switching valves were replaced. The manufacturer was not made aware of the failure. The failure mileage was approximately 172,000.

5 Manifold/header/muffler/tail Pipe problem of the 2007 Toyota 4Runner

Failure Date: 03/01/2017

Exhaust manifolds on the 4. 7 v8 crack where the catalytic converter is welded to the exhaust manifold,causing exhaust leaks. This is a very expensive repair for the owner of the vehicle.

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6 Manifold/header/muffler/tail Pipe problem of the 2004 Toyota 4Runner

Failure Date: 10/01/2016

Frame has way too much rust for a vehicle of this age. Exhaust manifold ticking noise. Both are well documented issues with this model year. . . .

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7 Manifold/header/muffler/tail Pipe problem of the 2005 Toyota 4Runner

Failure Date: 12/11/2013

Leaking exhaust manifolds due to faulty design this is on the v8 4runner. Exhaust will go into the cabin of the vehicle and smell like rotten eggs. Toyota will not help in the replacement of these manifolds. The charge is 2500 to replace. There is a technical service bulletin on this issue. It is hard to drive with exhaust leaking in the cab sometimes getting sick.

8 Manifold/header/muffler/tail Pipe problem of the 2000 Toyota 4Runner

Failure Date: 11/12/2012

Frame rust-through - vehicle's frame has prematurely rusted through from the inside-out along passenger side in area of muffler assembly.

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9 Manifold/header/muffler/tail Pipe problem of the 2006 Toyota 4Runner

Failure Date: 03/16/2012

The contact owns a 2006 Toyota 4runner. The contact stated that the vehicle would become wobbly when driving at speeds over 60 mph. The contact took the vehicle to the dealer and was told hat the hydro-booster pump needed to be replaced. The contact stated that the check engine light was also illuminated. The dealer stated that the catalytic converter and manifold also needed to be replaced. The vehicle was repaired. The failure mileage was unknown, but the current mileage was 61,000.

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10 Manifold/header/muffler/tail Pipe problem of the 2005 Toyota 4Runner

Failure Date: 01/01/2010

2005 Toyota 4 runner exhaust manifold cracks.

11 Manifold/header/muffler/tail Pipe problem of the 2002 Toyota 4Runner

Failure Date: 11/27/2008

The contact owns a 2002 Toyota 4runner. While driving 60 mph, the contact heard the piston connecting rod pop when he switched lanes. As a result, oil leaked out of the engine manifold and caused a fire. The vehicle was towed to the dealer and they stated that there was catastrophic failure to the engine. The dealer notified the manufacturer to repair the engine. The current and failure mileages were 127,000.

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12 Manifold/header/muffler/tail Pipe problem of the 2002 Toyota 4Runner

Failure Date: 09/07/2005

2002 Toyota 4 runner - the oil is getting thick and gelling. The vehicle is using a lot of oil, and blowing black smoke came from the tail pipe. The dealer said this was a common problem for some Toyota of this year, make and models, and Toyota did have the highest amount of complaints on the consumer complaint website. It started to blow the black smoke driving. Took vehicle to dealer, and the dealership said it was a oil gelling problem. Dealership stated that the motor would have to be torn to find out what caused this problem. This would be at the consumer's expense. Manufacturer said they would not be able to help the consumer with this problem. There was an extended warranty on this vehicle, and the manufacturer stated that this would not be covered due to the maintenance that had done on the vehicle.

13 Manifold/header/muffler/tail Pipe problem of the 1996 Toyota 4Runner

Failure Date: 11/05/2004

Oil sludge problem. Coolant is leaking and oil sludge is building up within the manifold. It is using 2 to 3 quarts of oil on a monthly basis and smoking will badly when first cranked. Car checked by Toyota dealership and says nothing is wrong with car.

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14 Manifold/header/muffler/tail Pipe problem of the 2004 Toyota 4Runner

Failure Date: 03/09/2004

When driving my 2004 Toyota 4 runner emits a sulfur like odor. I have been told that switching fuels will help, but I have tried all fuels in the area of all grades and still have this terrible smell. It happens on a repeatable basis, most of the time after exiting the freeway onto a surface street is when it is most noticeable.

15 Manifold/header/muffler/tail Pipe problem of the 2003 Toyota 4Runner

Failure Date: 06/09/2003

Rear window is open and exhaust smoke fumes will come inside of window while traveling.

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16 Manifold/header/muffler/tail Pipe problem of the 2003 Toyota 4Runner

Failure Date: 06/01/2003

Rotten egg (sulfur) smell with carbon monoxide (CO) in the cabin is making passengers sick! (poisoned) I just did a little research on this problem and have learned that 60 complaints have been submitted to the NHTSA for this sulfur smell. However what everyone is focusing on is the smell of rotten egg. This is disgusting and potentially dangerous but that is it is not what will kill you. The carbon monoxide(CO)is the real danger because it is without odor and deadly it is also getting into the car by the same means as the obvious egg smell. I was so concerned that I contacted a enviromental company who came for a ride along in my 2003 sr5 4runner. This ride proved to me that(CO)is indeed entering the cabin and alarmed the tech who came along with a (CO)tester. At one point he yelled "close the f@#%@%& rear window". I saw the readings go off the charts depending on the configuration of the windows. I did not pay for this test as they were being kind enough to just see if I had any (CO)entering the cabin. This was enough for me! I have since contacted Toyota customer service and I am waiting to hear from the regional rep from FL. Another option for people to find out on their own is to go to the home depot and buy a (CO) tester. This can be plugged into the 110 outlet in the glove box. I did and I do not drive with the rear window down at all any longer and have postponed trips of longer than 50 miles to reduce exposer to this harmful chemical. This is a serious problem that may be corrected by changing the location of the tail pipe to vent to the side of the vehicle. I hope this will get the people (NHTSA) who are supposed to be professionals that protect us "to wake up. " if someone else could do a similar test in their state we could have more ammunition to fight Toyota. I have found out that the epa company would do a complete test with report and all for around $340. 00. I am going to see if the service rep would do this but I doubt it.

17 Manifold/header/muffler/tail Pipe problem of the 2003 Toyota 4Runner

Failure Date: 06/01/2003

Rotten egg sulfur smell with carbon monoxide (CO) in the cabin is making passengers sick! (poisoned) I just did a little research on this problem and have learned that 60 complaints have been submitted to the NHTSA for this sulfur smell. However what everyone is focusing on is the smell of rotten egg. This is disgusting and potentially dangerous but that is it is not what will kill you. The carbon monoxide(CO)is the real danger because it is without odor and deadly it is also getting into the car by the same means as the obvious egg smell. I was so concerned that I contacted a enviromental company who came for a ride along in my 2003 sr5 4runner. This ride proved to me that(CO)is indeed entering the cabin and alarmed the tech who came along with a (CO)tester. At one point he yelled "close the f@#%@%& rear window". I saw the readings go off the charts depending on the configuration of the windows. I did not pay for this test as they were being kind enough to just see if I had any (CO)entering the cabin. This was enough for me! I have since contacted Toyota customer service and I am waiting to hear from the regional rep from FL. Another option for people to find out on their own is to go to the home depot and buy a (CO) tester. This can be plugged into the 110 outlet in the glove box. I did and I do not drive with the rear window down at all any longer and have postponed trips of longer than 50 miles to reduce exposer to this harmful chemical. This is a serious problem that may be corrected by changing the location of the tail pipe to vent to the side of the vehicle. I hope this will get the people (NHTSA) who are supposed to be professionals that protect us "to wake up. " if someone else could do a similar test in their state we could have more ammunition to fight Toyota. I have found out that the epa company would do a complete test with report and all for around $340. 00. I am going to see if the service rep would do this but I doubt it.

18 Manifold/header/muffler/tail Pipe problem of the 2000 Toyota 4Runner

Failure Date: 05/04/2003

The consumer noticed smoke coming from the tail pipe and hood. The dealer stated the engine had sludge build up caused by failure to provide proper maintenance.

19 Manifold/header/muffler/tail Pipe problem of the 2003 Toyota 4Runner

Failure Date: 05/01/2003

My 2003 Toyota 4 runner has an extremely strong smell of sulphur in the cabin when I drive with the windows open. I have reported this 3 times to my dealer, and on the third time, they acknowledged that the smell was from the fuel. I have owned many cars, and never experienced such a smell, and I have compared to other 4runner owners, all of whom have the same situation. The smell is immediately noticeable.


Other Common Engine And Engine Cooling related problems of Toyota 4Runner


Safety Ratings of 4Runner Cars
Fuel Economy of 4Runner Vehicles
4Runner Service Bulletins
4Runner Safety Recalls
4Runner Defect Investigations