Frame Rust Problems of Toyota FJ Cruiser - part 2

While driving normally and less than 10 miles per hour, thankfully on a regular, paved, local road with little traffic, the driver side rear suspension spring seat and stabilizer bar attachment point on rear axle suddenly, unexpectedly, and without warning just tore apart and off of the axle housing to which it was mounted and the resulting sharp and heavy metal edged parts completely sheared off a brake line releasing all hydraulic brake fluid and causing the immediate loss of all normal braking ability. Thankfully nobody was injured, but the car can't be driven at all now, because it has no brakes at all, other than the mechanical emergency brake, and by using transmission "braking. " lots of rust under car since we bought it used from dealer in morristown NJ, apparently due to low quality steel used in initial construction and apparent lack of adequate factory anti-rust treatment of frame and other undercarriage parts. Interior and painted top body parts show no rust issues. However, the underside, is full of lots of rust. This is apparently a well-known, very common problem with Toyota fj models. It is very dangerous, and it should be addressed by Toyota immediately! I'm making plans to have the car towed to a local Toyota dealership for inspection and possible repairs. Finally, as far as I am aware, this car has never done any significant or taxing "off-roading. ".

See all problems of the 2007 Toyota FJ Cruiser 🔎.

Frame completely rusted away from body of car. Engine and exterior body are in perfect condition due to the rusted out frame Toyota claims the car is unsafe to drive and they will not touch it. See attached . The frame looks like a pastry would as it flakes away in layers until there is nothing left.

During 2019-2020 state inspection of 2007 Fj Cruiser with 78000 miles by dealer was told that frame is so rusted that it probably would not pass the next inspection. Explanation given was that Toyota does not make their frames as thick as other makes. This vehicle was used as a daily driver, not much off-road and no serious off-roading. I work from home, so most years less than 5000 miles driven. Also have had to replace front brake calipers for the past 3 years.

Rust has decimated the frame of this vehicle resulting in the control arm mount to break away from the frame of the vehicle. The control arm is completely in tact. The part that broke is irreparable because it is the frame itself. No welding/body shop will touch it because they deem it unsafe even if welded back to rest of frame. It is being recommended not to attempt a repair and to install a new frame. Fortunately, this broke in a parking lot instead of on the highway where an accident would have happened or worse. Frame rust has been a problem with Toyota trucks as I understand but to have a frame actually break is absurd.

Rust found in the frame throughout, tank straps as well.

2007 Toyota Fj Cruiser, 125k miles. Mid-atlantic area of the us. Frame has excessive rust and degradation. A Toyota dealership during a normal service visit and 2 independent mechanics confirm it is unsafe to drive or to especially tow trailers. Both independent mechanics also added they have seen this issue before on tundras, Fj Cruisers, and 4runners from the same era. Weldments in the frame are corroded and riddled with cracks. Large sections of frame members are also very corroded with thin walls/holes. Biggest concern is loss of structural integrity which could lead to a major mechanical failure/accident. Little to no rust on the body, have driven other Toyota and Ford trucks in same environment with no rust issues at 200k miles. Filed a complaint with Toyota.

Frame is rusting & cracked in various places. Gas tank strap rusted / corroded completely off leaving gas tank sagging in the rear. This has all happened over time.

Frame is rusting badly.

My Fj Cruiser frame is rotting from the inside out, the gas tank mounting strap has broken and due to frame rust, the mounting point has failed and broken off the frame. The rear body mounts are deteriorating as is the rear frame cross members. Due to the frame ruat and gas strap mounting point failing, the dealer cannot repair. This is a safety issue as the gas tank cannot be correctly mounted. Of the 2nd gas tank strap fails, the gas tank may fall out. I have seen several bodyshops that are surprised at the age of the vehicle and the amount of frame rot present.

Excessive rust of the frame. Have found multiple holes in structural areas such as the transmission cross member welds meeting the frame. Failure of the frame coating all over. Frame rot from the inside causing holes from the inside out. Also rusting from areas such as control arms, rear end links, and differential mounts. Will provide more pictures when I have the availability to do so.

Frame rust, rear bumper rush, under carriage rust, front lower a-arm rust, differential rust.

See all problems of the 2013 Toyota FJ Cruiser 🔎.

I have been dealing with rust on the frame the frame is rusting from the inside out also dealing with rust on the tank straps.

I am reporting the issue of frame rust and corrosion of the fuel tank straps. The amount of corrosion and frame flaking is alarming and poses a huge safety issue for my family, other drivers and myself. Since purchasing the vehicle I have done everything I can to maintain and fix this issue including complaining to Toyota themselves with little to no success. The amount of rust compared to my other vehicle is completely out of proportion. Body mounts are flaking and crumbling and the frame is corroded and falling apart from the inside out.

Extensive frame rust, heavy rust on rear crossmember and rear axle, body mounts.

See all problems of the 2008 Toyota FJ Cruiser 🔎.

Frame rust on this vehicle is overwhelming. It is corroding extensively, even having taken steps to treat it and prevent further disintegration. Having descaled the frame and many components and treating everything with a rust conversion product and sealer, much of it is still coming back through. This is even after avoiding driving under any negative weather conditions. There are many places that the rust is just eating its way back through again. There are individual parts that could be broken off by hand due to the rust. Although it seems to be fairly stable at the moment, I am unsure how long the frame and structure may stay intact before there is a major malfunction. This includes the gas tank strap that is rusting through as well.

Excessive rust on the frame and undercarriage. Needed to be cleaned and treated.

While driving, my exhaust broke from hitting a pothole. When I took to the shop for repair, we noticed so much rust on the frame. I made an appointment at my local dealership to have it inspected, we found that the frame is extremely rusted with holes in the back piece by the bumper. The local dealership opened a case. They also said for me to contact corporate Toyota and open a case. The local dealership said they take this extremely serious because of the tacoma rusted frame recall. The dealership said they can not make a decision and that it must be made by corporate. The dealership supplied the pictures so corporate could see the frame rotting. I stayed in constant contact with a dealership representative the entire time. Every conversation that I had with Toyota corporate ends with them saying �sorry, there is not a recall right now�. The dealership representative became frustrated and even said she would not put her kids in the Fj Cruiser because its unsafe. Everyone agrees that a 2007 Fj Cruiser frame should not be rusting out like this. Finally, the dealership was who told me I should contact NHTSA and start this process. I have been reading on fj criuiser specific forums recently about others having the same issue. It seems really wide spread.

Excessive frame rust rear body mount .

Rust on frame and underbody of vehicle corrosion beyond normal for vehicle.

Took the vehicle in for oil change and check a transmission fluid leak. Dealer found large amounts of rust on frame and suspension and noted, "not recommended to drive. ".

Frame rust - frame is rusted so bad mechanic and local deal said vehicle is not road worthy. If I had not taken my vehicle to a mechanic before service and general maintenance repairs, I would have driven on a 2400 mile vacation across country without knowing the danger of a failing frame. My initial complaint is I was unaware of any frame issues with Toyota trucks, there should have been a general recall/inspection of all Toyota frame vehicles for safety inspections. Second complaint is there is no resolution at this time, mechanic said it could take months to get an answer from Toyota and even then not sure they will fix it. Now I am without a vehicle.

The national highway traffic safety administration needs to open an investigation into reports of frame rust and corrosion problems for the 2007 � 2014 Toyota Fj Cruiser. This is the same ongoing safety problem as the several past recalls on other full framed Toyota vehicles. Excessive frame corrosion �rot� starting in jointed metals within the frame structures is rusting from the outside and the inside out. In recent observations non-jointed rust metal is also suffering rust through in other parts of these frames. My personal vehicle exhibits all the signs of excessive rusting including one rust through hole at the rear cross member location underneath the rear bumper. This location is neither accessible nor visible without the bumper removed. The opposite side of the cross member exhibits large sever flaking rust present both outside and inside the frame. The main frame, location behind the front wheel, exhibits severs large flaking rust inside the frame. The outside within this area also contains a half size dollar rust area through the first frame layer that initially appeared as surface rust. In conclusion what appeared as normal surface rust can indeed be structural integrity concerns. The frame is rusting inside out at an alarming fast rate, much faster than the 60's fj40 frames I have restoration experience with. I was informed per my dealership the rust would be documented but not considered abnormal and no recall was in place.

Lower control arms rusted. Need replaced couldn't adjust them for alignment. Frame rusting front and rear diff rusting. Stock skid plate replaced rusted through completely. I thoroughly wash salt off my vehicle, yet it still has rusted just like the original frame recall Toyota hasn't gotten it right. Need another recall. I've lived with mine, but others have it much worse.

See all problems of the 2011 Toyota FJ Cruiser 🔎.

Frame is rusting to the point it is about to break.

The rust on the frame is mind blowing. Rust holes in frame and gas tank straps, and suspension parts. This is dangers and someone can be injured or dead.

I am the original owner of the vehicle with excessive frame rust occurring within 4 years of owning the vehicle. The rust is so excessive that the Toyota deemed the car too damaged to drive because a majority of the frame was too week and, therefore unsafe to drive.

Vehicle is showing excessive rust on the frame and under-body. I have an older vehicle that almost has no rust. Rust on the 2007 Fj Cruiser is mainly on the frame joints and the rear axle. Car was daily commuter for about 5 years and then became a leisure vehicle driven mainly on weekends and outings.

Frame has rust throughout. Had to replace gas straps because rusted through and broke. Repair axel bearing.

Frame is severely rusted, has cracks & corrosion, & is unsafe to drive.

Severe rusting on the frame. Vehicle feels very loose while driving or hitting a bumb as rust progresses.

Excessive rust on the frame. Vehicle is maintained very well, but frame rust continues to get worse. This is a known issue with the Fj Cruiser on all the forms online. Toyota has yet to file a recall on our vehicles. Other Toyota vehicles that use the same frame have already been recalled. There are thousands of us with a rotting in frames and Toyota will do nothing.

Since I purchased the vehicle brand new in 2006 it has been rusting and an alarming rate. Even my mechanic says he's never seen a new car rust that quickly. The frame is covered I rust, I tried to stop it but it didn't work.