2004 Toyota 4RUNNER

612 complaints on file, page 1 of 31.

1. Filed Jun 14, 2026Failure May 27, 2026Bowling Green, OHUnknown or other

   I was informed by my mechanic that my vehicle has extensive rust and corrosion on the vehicle frame.I understand there was a recall on this issue by Toyota but did not include this model year. This issue affects not only driver safety but also resale value.

   NHTSA complaint 11744022
2. Filed Dec 29, 2025Failure Dec 28, 2025Jameson, MOAir bags, Body, SuspensionCrash1 injured

   What component or system failed or malfunctioned, and is it available for inspection upon request? Response: Frame, Suspension, Airbags / Yes it is available for inspection. How was your safety or the safety of others put at risk? Response: Safety was put at risk due to frame & suspension failure due to severe rust. Also due to failure of deployment of AirBags. Rusted Frame Failure subsequently caused safety of Injured Party and other motorists to be at risk due to the Injured Party’s 4Runner to dart across oncoming lane of traffic with no warning other than a swaying motion felt immediately before losing control. Once the Injured Party lost control of the 4Runner it crossed into oncoming traffic, progressing into the drainage ditch on the oncoming traffic side of highway. Once the 4Runner impacted the drainage ditch at a 90° angle, the 4Runners momentum dispersed by causing the 4Runner to overturn 3 times landing on its wheels in the adjoining field. Has the problem been reproduced or confirmed by a dealer or independent service center? Repaonse: Independent Service Center has confirmed the problem with the Rusted Frame, Rusted Suspension, and Air Bag failure. Has the vehicle or component been inspected by the manufacturer, police, insurance representatives or others? Response : Yes Were there any warning lamps, messages or other symptoms of the problem prior to the failure, and when did they first appear? Repaint: No warning lamps prior to failure. Symptoms indicative of failure were an unknown minor swaying sensation while driving. Injured party was under the impression that there may have been a tire low on air, which was discovered to be incorrect later.

   NHTSA complaint 11707650
3. Filed Aug 31, 2025Failure Aug 21, 2025Bayonne, NJUnknown or other

   The body frame on this vehicle is almost completely rushed out. I don’t know what to do. If I should have the frame replaced I know there’s been a couple recalls on similar Toyota models.

   NHTSA complaint 11684174
4. Filed Aug 29, 2025Failure Aug 29, 2023120,000 milesFarmington Hills, MIFrame and members

   The contact owns a 2004 Toyota 4Runner. The contact stated that while the vehicle was in for service, the independent mechanic discovered rust on the front driver's side subframe. Additionally, the subframe had developed holes due to rust. The cause of the failures was not yet determined, and the vehicle was not yet repaired. The manufacturer and local dealer were notified of the failure, but no assistance was offered. The failure mileage was 120,000.

   NHTSA complaint 11683937
5. Filed Aug 19, 2025Failure Aug 19, 2025108,000 milesGold Hill, NCStructure

   The contact owns a 2004 Toyota 4-Runner. The contact stated that the frame was severely rusted. The vehicle was not diagnosed or repaired by an independent mechanic or a dealer. The manufacturer was notified of the failure and referred the contact to the NHTSA Hotline for assistance. The failure mileage was approximately 108,000.

   NHTSA complaint 11681545
6. Filed Aug 9, 2025Failure Jul 27, 2025Elyria, OHPower train, Body

   2004 Toyota 4Runner SR5 - Frame rust: currently not drivable due to complete breakage from the rust. Driving 2 hours home on the highway I almost lost control, pressing/releasing the brake and/or gas pulls the steering side to side and sways the truck (fish tail) due to damage from the frame rust/breaking. There is no control of the rear end. Truck was in great condition prior to the frame snapping. Vehicle has been inspected by multiple mechanics (including Firestone, Welding/fabricating Auto Repair shops and small owned mechanic shops), possibly won’t be able to weld due to the amount of rust. Firestone won’t perform any service if the vehicle needs to go in the air (tires, oil..etc) due to frame rust. This has been a huge problem with Toyota, they addressed other models around the same year but excluded the 4Runner for unknown reasons. The dealership will not address the issue unless instructed by corporate. This problem jeopardized my safety and the safety of others around while I was driving at highway speeds, there was no warning when it occurred. Vehicle is available for inspection any time, as it currently is not going anywhere without a tow.

   NHTSA complaint 11679499
7. Filed Jul 27, 2025Failure Jul 27, 2025Sarasota, FLUnknown or other

   Rusting frame, no specific incident date. Used today’s date.

   NHTSA complaint 11676481
8. Filed Jun 27, 2025Failure Jan 1, 2025Lakeville, MNBody

   Frame rust. Huge problems on the 4th gen 4runners. Can't believe there's not a recall on this issue.

   NHTSA complaint 11669616
9. Filed Apr 3, 2025Failure Apr 3, 2025Windsor Locks, CTUnknown or other

   Excessive frame and suspension corrosion that could lead to serious accidents if not repaired at a very high cost for myself

   NHTSA complaint 11652622
10. Filed Feb 26, 2025Failure Oct 17, 2022Virginia Beach, VABody

    The undercarriage is full of rust that the repair shop will not test drive or fix due to the issue. No warnings.

    NHTSA complaint 11645055
11. Filed Feb 7, 2025Failure Nov 29, 2024Highlands Ranch, COBody

    Extensive frame rust to the point of structural failure. Cannot support weight or force.

    NHTSA complaint 11641362
12. Filed Oct 20, 2024Failure Nov 15, 2016Minooka, ILElectrical system, Body, Suspension

    Rusty frame undercarriage. It’s not going to get any better due to the fact I have to drive on hwy 80 with all the construction, that’s a hazard itself, potholes everywhere that puts stress on your frame and the salt every winter.

    NHTSA complaint 11620842
13. Filed Oct 16, 2024Failure Apr 27, 2022Lexington, KYUnknown or other

    Underbody of vehicle is rusting away from vehicle body, I was made aware of situation at a service appointment in April of 2022, no vehicle collision or wreck has happened because of it yet,

    NHTSA complaint 11620033
14. Filed Sep 22, 2024Failure Mar 6, 2024Schaumburg, ILService brakes, Body, Suspension

    UNKNOWN: Excessive frame rust. frame is excessively rusting to the point where the brakes and suspensions is connected to the frame has been compromised. brake lines rusted to the point of failure, thus almost causing a wreck. Vehicle is now parked due to safety concerns involving the excessive rusting that is happening to the frame and any components that is attached to the frame.

    NHTSA complaint 11615836
15. Filed Sep 19, 2024Failure Sep 18, 2024Ridgewood queens, NYBody

    Undercarriage frame rusted to the point where structural rust was formed in various places This rust has made a whole and cracks to the frame causing my vehicle to become a safety hazard on the road

    NHTSA complaint 11615331
16. Filed Aug 22, 2024Failure Aug 22, 2024Honolulu, HISuspension

    I recently bought a 2004 Toyota 4 Runner and the frame of the vehicle has significant corrosion to the extent of holes, weld failures and more. I've never seen frame rust so bad on a vehicle like this. I'm a little uneasy about the safety of this situation. I think Toyota should replace the frame or give a good discount on the part and labor. I hope someone can help me out with this concern.

    NHTSA complaint 11610346
17. Filed Jul 18, 2024Failure Jul 17, 2024Rolling Meadows, ILBody, Suspension

    Cars frame is rotting out to the point it is not safe to drive. I was told being in a collision could cause catastrophic failure and the car is just turning 20 years old with 125,000 miles. Can’t get my money back and the car is otherwise is excellent condition.

    NHTSA complaint 11603298
18. Filed Jun 12, 2024Failure Jun 12, 2024Sheboygan, WISuspension, Unknown or other

    Frame is severely rusted and has holes started at 40k miles

    NHTSA complaint 11593920
19. Filed May 15, 2024Failure May 3, 2024Bothell, WACarry handle, Shell, Base, Chest clip

    Something is causing the straps to fray I was informed this is a a problem, checked my seat and sure enough my straps are fraying. Evenflo says it’s my fault.

    NHTSA complaint 11588810
20. Filed Mar 22, 2024Failure Mar 21, 2024Harris, MOSteering, Body, Suspension

    Took 2004 Toyota 4Runner SR5 to Toyota dealership to be serviced. Dealership called me to explain unable to do alignment, due to rear back frame excessive rusted through. Dealership advised waste of money to align new tires just purchased, unable to even do alignment and it was dangerous. Now what is to be done? This is my daily driver for work. How did this happen that its unsafe and dangerous to drive.

    NHTSA complaint 11578947