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2001 Toyota 4runner Body & Structure Problems

66 owner-reported body & structure complaints from NHTSA data

66
Complaints
Jan 2019Dec 2019
Date Range

Data sourced from NHTSA public database. For informational purposes only. Always consult a qualified mechanic.

Owner Complaints (66)

criticalSTRUCTURE
Filed: May 2020

Your 4Runner's frame has rusted so severely that pieces are breaking off by hand, and a technician discovered it won't pass vehicle inspection in its current state. The frame deterioration is so advanced that welding was needed as an immediate safety repair, though this is only a temporary fix—the overall structural condition remains heavily compromised. The repair involved grinding out the rusted sections and welding in new steel to restore structural integrity.

NHTSA #: 11323539
criticalSTRUCTURE
Filed: Mar 2020

Your 4Runner failed its safety inspection because the frame has significant rust and rot, making it unsafe to drive. Toyota declined to help with repairs, and the previous owner won't assist either. You may need professional frame inspection and rust repair to make the vehicle roadworthy again.

NHTSA #: 11316298
criticalSTRUCTURE,UNKNOWN OR OTHER
Filed: Dec 2019

Your 2001 4Runner has rust that has eaten completely through the frame, causing it to fail inspection. Toyota has issued recalls for frame rust on thousands of similar trucks, but your vehicle isn't covered under that recall. Toyota customer service has refused to repair, replace, or buy back your truck despite others receiving those remedies for the same issue.

NHTSA #: 11292332
criticalSTRUCTURE
Filed: Sep 2019

Your vehicle's frame is severely rusted, and the dealer found that the trailing arm mount (where the suspension connects to the frame) is almost completely corroded away. The dealer won't perform the transfer case repair because they believe the frame is unsafe and at risk of breaking through. You may need to replace your vehicle, as the frame damage is structural and severe.

NHTSA #: 11253813
criticalSTRUCTURE
Filed: Feb 2019

Your vehicle's frame has severe rust damage in multiple locations, which has weakened the structural integrity. The suspension components have actually broken through the rotted frame, creating an unsafe driving condition. This rust-related structural failure poses a serious safety risk and the vehicle should not be driven until repairs are made. Fixing this will likely require frame repair or replacement, along with inspection and repair of the suspension components.

NHTSA #: 11181293
criticalSTRUCTURE
Filed: Jan 2019

Your 4Runner's frame has severe rust with holes that have eaten completely through the metal, even though the body exterior looks fine. Your husband is concerned the vehicle is unsafe to drive because in a collision, the weakened frame could crumple easily rather than protect you. Fixing this would likely involve professional frame inspection, rust treatment, and possibly frame reinforcement or replacement of corroded sections.

NHTSA #: 11166521
highSTRUCTURE
Filed: Dec 2021

Your 4Runner's frame has developed significant rust and rot, along with other rust-related damage throughout the vehicle. This is a structural integrity issue that should be inspected by a professional to determine what repairs or reinforcement may be needed.

NHTSA #: 11443914
highSTRUCTURE
Filed: Aug 2021

You noticed your 4Runner swaying while driving. A mechanic discovered severe rust on the sub frame between the sway bar and differential, which affects the vehicle's structural integrity and handling. The dealer determined the sub frame needs to be replaced but declined to perform the work due to its complexity. Fixing this will require replacing the sub frame assembly, a major structural repair.

NHTSA #: 11429329
highSTRUCTURE
Filed: Jun 2019

Your vehicle's frame is experiencing significant corrosion and rust damage. This is similar to frame problems that affected some Toyota Tacoma models that were recalled. Frame corrosion can weaken the structural integrity of your vehicle over time.

NHTSA #: 11217256
highSTRUCTURE
Filed: May 2019

You've noticed a distinct wobble while driving your 4Runner on the highway. A mechanic found a 1-inch-wide, 18-inch-long hole in the frame caused by rust, which they describe as a serious structural concern that welding might temporarily address. There may be additional hidden rust behind the gas tank that isn't visible. Fixing this will likely require professional frame welding or replacement of the affected frame section.

NHTSA #: 11217061
mediumSTRUCTURE,UNKNOWN OR OTHER
Filed: Dec 2018

FRAME RUST ISSUES. MY FRAME HAS BEEN RUSTING AWAY FOR THE ENTIRE TIME I'VE OWNED IT, AND IT ISN'T GETTING ANY BETTER. THE PASSENGER INSIDE FRAME RAIL IS RUSTED FROM THE REAR LOWER CONTROL ARM MOUNT TO THE CROSS MEMBER MOUNT MIDWAY DOWN THE FRAME. THE DRIVER INSIDE FRAME RAIL IS RUSTED AT THE LOWER CONTROL ARM MOUNT AS WELL, AND SLIGHTLY IN FRONT OF IT. WHEN I PURCHASED THE VEHICLE I NOTICED A SLIGHT PIT, AND DIDN'T THINK ANYTHING OF IT. OVER THE NEXT YEAR THAT PIT GOT BIGGER UNTIL THERE WAS A LARGE OPENING THAT YOU COULD FIT TWO HANDS INSIDE OF.

NHTSA #: 11163727
mediumSTRUCTURE,UNKNOWN OR OTHER
Filed: Oct 2018

"TAKATA RECALL" MY 2001 TOYOTA 4RUNNER FRAME IS RUSTED OUT AND WON'T PASS STATE INSPECTION.

NHTSA #: 11141704
mediumSTRUCTURE
Filed: Sep 2018

TL* THE CONTACT OWNS A 2001 TOYOTA 4RUNNER. THE CONTACT STATED THAT THE ENTIRE FRAME OF THE VEHICLE WAS RUSTED. THE VEHICLE WAS TAKEN TO NORTHWAY TOYOTA (727 NEW LOUDON RD, LATHAM, NY 12110, (888) 885-1583) AND THE CONTACT WAS INFORMED THAT THERE WAS NO RECALL TO COVER THE REPAIR. THE MANUFACTURER ECHOED THE DEALER'S STATEMENT AND ISSUED CASE NUMBER: 1809211044. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE FAILURE MILEAGE WAS 150,000.

NHTSA #: 11130606
mediumSTRUCTURE,UNKNOWN OR OTHER
Filed: Aug 2018

THE FRAME ON MY 2001 ROTTED VERY QUICKLY FROM THE INSIDE OUT. IT IS THE SAME EXACT FRAME USED ON THE TACOMA (WHICH WAS RECALLED) AND ON THE 2002 4RUNNER, WHICH IS CURRENTLY UNDER INVESTIGATION. IF I DIDN'T GET THE NECESSARY FRAME REPAIRS IT EASILY COULD HAVE CRACKED IN HALF WHEN ON THE ROAD. THE MAIN AREAS OF ROT ARE LOCATED AT THE REAR CONTROL ARM (WHICH I HAD PROFESSIONALLY REPAIRED), AND UP FRONT NEAR THE SUSPENSION AND AXLE. MY BROTHERS 1997 4RUNNER AXLE AND SUSPENSION COMPLETELY FELL APART WHEN HE WAS DRIVING ON THE ROAD. HE WAS LUCKY TO NOT BE ON THE HIGHWAY. SOMEONE DEFINITELY NEEDS TO LOOK INTO THIS ISSUE. I PURCHASED THE VEHICLE FROM THE SOUTH FOUR YEARS AGO (2014) WITH A SPOTLESS ROCK HARD FRAME. FOUR YEARS LATER THE REAR CONTROL ARM AREAS MENTIONED ABOVE COMPLETELY ROTTED THROUGH. THIS SHOULD NOT HAPPEN! I LOVE MY 4RUNNER, BUT I CAN'T BELIEVE HOW THESE TRUCK FRAMES WEREN'T RECALLED ALONG WITH THE TACOMA FRAMES. IT IS THE SAME EXACT FRAME...

NHTSA #: 11121576
mediumSTRUCTURE
Filed: Aug 2018

WENT FOR INSPECTION FOR 2001 TOYOTA 4 RUNNER. FRAME IS RUSTED AND TOO BAD. MECHANIC SAID UNSAFE TO BE ON THE ROAD. WHAT A SHAME EVERYTHING RUNS GOOD. NOW I AM WITHOUT A VEHICLE. THE TOYOTA 4 RUNNERS SHOULD HAVE BEEN RECALLED JUST LIKE THE TACOMA'S AND SEQUOIAS.

NHTSA #: 11115647
mediumSTRUCTURE,ENGINE
Filed: May 2018

TL* THE CONTACT OWNS A 2001 TOYOTA 4RUNNER. THE CONTACT STATED THAT THE CHECK ENGINE WARNING INDICATOR ILLUMINATED. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHERE THE TECHNICIAN INFORMED THE CONTACT THAT THE KNOCK SENSORS NEEDED TO BE REPLACED. THE TECHNICIAN ADVISED THE CONTACT NOT TO DRIVE THE VEHICLE BECAUSE THE FRAME WAS SEVERELY RUSTED. THE VEHICLE HAD NOT BEEN REPAIRED. THE MANUFACTURER AND DEALER WERE NOT MADE AWARE OF THE FAILURES. THE FAILURE MILEAGE WAS 256,518.

NHTSA #: 11098010
mediumSTRUCTURE
Filed: May 2018

FRAME OF VEHICLE HAS SEVERE RUST DAMAGE THROUGHOUT, TOLD BY STATE SAFETY INSPECTOR THAT IT IS BEYOND REPAIR. APPEARS TO HAVE OCCURRED SLOWLY OVER THE COURSE OF MANY YEARS.

NHTSA #: 11097628
mediumSTRUCTURE
Filed: Aug 2017

I WAS AT THE TOYOTA DEALERSHIP HAVING MY BRAKELINE ON THE FRONT LEFTSIDE REPAIRED, AFTER HITTING A POTHOLE; AND I WAS TOLD BY PHONE, MY FRAME IS BADLY RUSTED THROUGH IN MULTIPLE SPOTS.

NHTSA #: 11020669
mediumSTRUCTURE
Filed: Jul 2017

TL* THE CONTACT OWNS A 2001 TOYOTA 4RUNNER. WHILE DRIVING 40 MPH, THE FRAME FAILED WITHOUT WARNING AND CAUSED THE VEHICLE TO WOBBLE. THE VEHICLE WAS DRIVEN HOME WHERE IT WAS PIECED BACK TOGETHER. THE DEALER AND MANUFACTURER WERE NOT CONTACTED. THE FAILURE MILEAGE WAS APPROXIMATELY 180,000. UPDATED 11/13/17 *BF THE CONSUMER STATED THE FRAME RUSTED. UPDATED 11/16/2017*JS

NHTSA #: 11011779
mediumSTRUCTURE
Filed: Jun 2017

FRAME RUSTED THROUGH IN SEVERAL PLACES. UNSAFE TO DRIVE.

NHTSA #: 11000295
mediumSTRUCTURE
Filed: Mar 2017

MY FRAME HAS RUSTED OUT. I HAVE KEPT IT VERY CLEAN AND PROTECTED BUT STILL IS RUSTING.

NHTSA #: 10967783
mediumSTRUCTURE
Filed: Mar 2017

TL* THE CONTACT OWNS A 2001 TOYOTA 4RUNNER. THE CONTACT STATED THAT THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC FOR MAINTENANCE. THE MECHANIC NOTICED SEVERE RUST UNDER THE VEHICLE AND PIECES OF METAL FALLING OUT BY CHUNKS, INCLUDING THE FRAME. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE VEHICLE WAS NOT REPAIRED. THE APPROXIMATE FAILURE MILEAGE WAS 143,000.

NHTSA #: 10966336
mediumSTRUCTURE
Filed: Nov 2016

TL* THE CONTACT OWNS A 2001 TOYOTA 4RUNNER. WHILE THE VEHICLE WAS UNDERGOING ROUTINE MAINTENANCE, THE CONTACT WAS INFORMED THAT THE REAR PASSENGER SIDE SUBFRAME DISPLAYED EXCESSIVE CORROSION. THE CONTACT WAS INFORMED THAT THE VEHICLE WAS UNSAFE AND SHOULD NOT BE DRIVEN. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 125,063.

NHTSA #: 10927638
mediumSTRUCTURE
Filed: Nov 2016

THE CHASIS RUSTS AND IS DAMAGED ON THE PASSENGER SIDE ABOUT 18 INCHES.

NHTSA #: 10925753
mediumSTRUCTURE
Filed: Oct 2016

FRAME HAS RUSTED THROUGH THE FRAME RAILS IN MULTIPLE AREAS. ISSUE WAS NOT DISCLOSED WHEN THE VEHICLE WAS PURCHASED 01/13/2015, YET I FOUND A REPAIR ORDER FROM 09/24/2014 THAT STATED THERE WERE RUST HOLES IN THE FRAME. DEALER IS CURRENTLY INSPECTING THE EXTENT OF THE FRAME DAMAGE AND WILL RECOMMEND A RESOLUTION. I HAVE SEVERAL PHOTOS, BUT CURRENTLY DO NOT HAVE THEM HANDY.

NHTSA #: 10918674
mediumSTRUCTURE
Filed: Oct 2016

FRAME RUSTING OUT. EXTERIOR OF TRUCK HAS NO RUST 170K MILES ON 4RUNNER

NHTSA #: 10914056
mediumSTRUCTURE
Filed: Aug 2016

THE FRAME IS ROTTING AND THE 4RUNNER IS UNSAFE.

NHTSA #: 10898383
mediumSTRUCTURE
Filed: Aug 2016

THE ISSUE WITH MY TOYOTA IS A RUSTED FRAME...RUSTED TO THE POINT THAT I WAS ADVISED TO PARK IT AND NEVER DRIVE IT AGAIN WITHOUT A NEW FRAME. ALTHOUGH IT IS A 2001 WITH 193,000 MILES, IT MECHANICALLY IS IN GREAT CONDITION. EXTERIOR AND INTERIOR IN GOOD CONDITION, AS WELL. I FIRST NOTICED THE VEHICLE HAD A FLOATING SENSATION ON THE HIGHWAY, AT TIMES FEELING LIKE I HAD NO CONTROL WITH THE STEERING WHEEL. AFTER ANOTHER 1-2 HRS OF DRIVING, I NOTICED THAT WHEN DRIVING OVER BUMPS OR DIPS IN THE ROAD, THE TRUCK WOULD ROCK SLIGHTLY SIDE TO SIDE. IT WAS SIGNIFICANT ENOUGH THAT ITEMS IN MY BACK SEAT ROCKED, AS WELL. AFTER SEVERAL MORE DAYS AND HOURS OF DRIVE-TIME THEREAFTER, THE ROCK ADVANCED TO THE POINT WHERE MY ENTIRE VEHICLE WAS ROCKING SO VIOLENTLY WHEN CROSSING A BRIDGE @40MPH, I HAD NO CONTROL OVER THE VEHICLE. EVEN BRAKING DID NOT IMMEDIATELY STOP THE ROCKING. AFTER THAT INCIDENT, I STOPPED DRIVING THE VEHICLE UNTIL I HAD IT SCHEDULED TO TAKE IN TO THE MECHANIC. THE PROBLEM WITH THE RUSTED FRAME WAS IDENTIFIED ALMOST IMMEDIATELY. I WAS TOLD THAT THE HOLES AND RUST WERE SO EXTENSIVE, THAT IT WAS ONLY A MATTER OF A SHORT AMOUNT OF TIME BEFORE THE FRAME WOULD NOT ONLY BREAK APART, BUT BREAK INTO SEVERAL PIECES. I WAS TOLD THAT IT WAS UNSAFE TO DRIVE AND THAT THE ONLY SOLUTION WAS A FRAME REPLACEMENT. I UNDERSTAND THAT TOYOTA HAD A RECALL ON THEIR TAUCOMA FRAMES FOR THAT SAME YEAR, BUT WILL NOT CORRECT THE IDENTICAL PROBLEM WITH THE 4RUNNER FRAME. I HAVE AN OTHERWISE WONDERFUL VEHICLE SITTING IN MY DRIVEWAY THAT IS TOO DANGEROUS TO DRIVE BECAUSE OF TOYOTA'S KNOWN, FAULTY, UNSAFE FRAME.

NHTSA #: 10895715
mediumSTRUCTURE
Filed: Jul 2016

TL* THE CONTACT OWNS A 2001 TOYOTA 4RUNNER. WHILE REPLACING THE SHOCKS ON THE VEHICLE, THE CONTACT NOTICED SEVERE RUST ON THE FRAME AND A HOLE APPROXIMATELY 3 AND 1/2 INCHES WIDE UNDER THE DRIVER SIDE. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED. THE APPROXIMATE FAILURE MILEAGE WAS 182,000.

NHTSA #: 10882627
mediumSTRUCTURE
Filed: Apr 2016

WHILE CHANGING MY OIL, I NOTICED A FEW NICE SIZE HOLES IN THE FRAME, IN FRONT AND BESIDES THE MUFFLER. I WONDERING IS IT SAFE FOR ME AND MY FAMILY TO DRIVE ON A REGULAR BASIS.

NHTSA #: 10860671
mediumSTRUCTURE
Filed: Apr 2016

MASSIVE RUST AND DETERIORATION ALONG INSIDE PANEL OF FRAME ON PASSENGER SIDE REVEALED ONCE EXHAUST SYSTEM WAS REMOVED FOR REPLACEMENT. DETERIORATED SECTION WAS ABOUT 24" LONG FROM REAR AXLE MOUNT TO CENTER STABILIZER BAR. UNKNOWN DETERIORATION ON DRIVER SIDE DUE TO LOCATION OF FUEL TANK.

NHTSA #: 10853250
mediumSTRUCTURE
Filed: Mar 2016

TL* THE CONTACT OWNS A 2001 TOYOTA 4RUNNER. WHILE PERFORMING AN OIL CHANGE, THE TECHNICIAN NOTICED THAT THE REAR PASSENGER SIDE OF THE FRAME WAS COMPLETELY CORRODED. THE TECHNICIAN STATED THAT THE FRAME HAD TO EITHER BE RE-WELDED OR REPLACED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS 160,000.

NHTSA #: 10851457
mediumSTRUCTURE
Filed: Feb 2016

MASSIVE RUST CORROSION AND PIECES BREAKING AWAY LOCATED UNDERNEATH ENTIRE VEHICLE. THE RUST WITH BREAKAGE HAS INTENSIFIED GREATLY IN THE LAST COUPLE OF YEARS AND REQUIRED WELDING THIS YEAR TO PASS INSPECTION BECAUSE THE VEHICLE WAS UNSAFE. THE WELDING CONSISTED OF WELDING THE FRAME RAIL WHERE THE REAR SUSPENSION MOUNTS AND A NEW BRACKET HAD TO BE WELDED ON THE AXLE HOUSING THAT HOLDS AN UPPER REAR STRUT ROD BECAUSE IT RUSTED OFF. BOTH WERE ON THE PASSENGER SIDE OF VEHICLE. THIS VEHICLE ONLY HAS 101,000 MILES AND IS WASHED AND WAXED ON A REGULAR BASIS.

NHTSA #: 10824784
mediumSTRUCTURE
Filed: Jan 2016

THE GRAM HAS RUST PERFORATION IN WHICH THE LEFT REAR CONTROL ARM HAS SEPARATED FROM THE FRAME. WHILE I WAS DRIVING A HEARD A POP AND STARTED TO LOSE PROPER CONTROL IN STEERING VEHICLE.

NHTSA #: 10822535
mediumSTRUCTURE
Filed: Dec 2015

MY 2001 TOYOTA 4 RUNNER WAS UP ON THE LIFT FOR REGULAR OIL CHANGE. A SERVICE TECH BROUGHT ME TO THE SERVICE BAY AND INFORMED ME OF A CONSIDERABLE AMOUNT OF RUST FAILURE OF THE FRAME. NOT SURFACE RUST, BUT RUST THAT IS CAUSING THE FRAME TO SEPARATE CAUSING VISIBLE CRACKS TO APPEAR. HE ADVISED ME OF THE POTENTIAL DANGER. HE ADVISED ME THAT TOYOTA HAS ADDRESSED THIS ISSUE ON TUNDRA'S, TACOMA'S AND SEQUOIA'S BUT OFFERS NO RELIEF FOR 4RUNNER OWNERS. THE VEHICLE HAS 137,000 MILES ON IT. MY GUESS WAS THAT I HAD ANOTHER 20-30,000 MORE TO GO AS IT DOESN'T TRAVEL MANY MILES ON A DAILY BASIS. SEEMS HARD TO REASON THAT TOYOTA HAS HAD REPLACEMENT PLANS IN PLACE FOR OTHER MODELS WITH THE SAME PROBLEM BUT NOT FOR THE 4RUNNER.

NHTSA #: 10811371
mediumSTRUCTURE
Filed: Aug 2015

THESE VEHICLES ARE NOTORIOUS FOR FRAME RUST/ROT. THE TACOMA OF THE SAME TIME PERIOD USED THE SAME FRAME AS THE 4RUNNER AND THE TACOMA HAS HAD A RECALL.

NHTSA #: 10749395
mediumSTRUCTURE
Filed: Jul 2015

TL* THE CONTACT OWNS A 2001 TOYOTA 4RUNNER. THE VEHICLE EXPERIENCED SEVERE CORROSION UNDERNEATH THE FRAME ADJACENT TO THE MUFFLER AND SUBFRAME. THE MECHANIC DIAGNOSED THAT THE FRAME AND SUBFRAME HAD SEVERE CORROSION. THE MANUFACTURER WAS MADE AWARE OF THE ISSUE. THE APPROXIMATE FAILURE MILEAGE WAS 130,000. MA 10/22/2015

NHTSA #: 10733935
mediumSTRUCTURE
Filed: Mar 2015

VEHICLE HAS A FRAME THAT IS RUSTED ON PASSENGER SIDE AND WAS TOLD BY A MECHANIC ON 3/20/15 THAT IT SHOULD BE IN A RECALL ASAP. DIFFERENTIAL COVER IS A RUSTED BULLET AND IS LEAKING. THERE IS NO CHANGING IT AS COVER IS A SOLID WELD NO BOLTS TO TAKE OFF TO CHANGE COVER. BRILLIANT IDEA BY TOYOTA. *TR

NHTSA #: 10700747
mediumSTRUCTURE
Filed: Mar 2015

THE FRAME ON MY 4RUNNER WILL NOT PASS INSPECTION DUE TO RUST, WHICH I NEED TO REPAIR. THE VEHICLE DOES NOT HAVE MUCH MILES ON IT AND SHOULD NOT RUST LIKE IT DID FROM THE INSIDE. THE RUST IS FROM THE INSIDE, WHICH MAKES IT VERY DANGEROUS TO HAVE ON THE ROAD ESPECIALLY IN STATES WHERE AN INSPECTION IS NOT REQUIRED. IT COULD EASILY GO UNNOTICED UNTIL IT IS TOO LATE, AND SOMEBODY COULD GET HURT OR KILLED WHEN THE FRAME FAILS. *TR

NHTSA #: 10694859
mediumSTRUCTURE
Filed: Nov 2014

TL* THE CONTACT OWNS A 2001 TOYOTA 4RUNNER. THE CONTACT STATED THAT WHILE HAVING MAINTENANCE PERFORMED, THE TECHNICIAN NOTIFIED THE CONTACT THAT THE FRAME WAS ROTTED DUE TO EXCESSIVE CORROSION. THE DEALER WAS CONTACTED AND MADE AWARE OF THE FAILURE. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS 204,507.

NHTSA #: 10659786
mediumSTRUCTURE
Filed: Oct 2014

THE BODY OF MY 2001 TOYOTA 4RUNNER IS COMPLETELY RUSTED OUT. RECENTLY, I BROUGHT THE VEHICLE TO A TOYOTA SERVICE CENTER WHO SUGGESTED THAT THE VEHICLE NO LONGER BE DRIVEN DUE TO SAFETY CONCERNS ASSOCIATED WITH DRIVING THE 4RUNNER IN ITS CURRENT CONDITION. I WAS TOLD THE FRAME WAS COMPLETELY RUSTED THROUGH, COMPROMISING THE INTEGRITY OF THE FRAME. *TR

NHTSA #: 10650429
mediumSTRUCTURE
Filed: Aug 2014

VEHICLE FAILED INSPECTION IN MAY 2014 DUE TO EXCESSIVE FRAME RUST AND PERFORATION. THE FRAME WAS RUSTED SO BADLY THAT THE SERVICE ADVISOR AT NEW ROCHELLE TOYOTA ADVISED "DUE TO EXCESSIVE FRAME PERFORATION DO NOT LET CUSTOMER DRIVE VEHICLE." *TR

NHTSA #: 10620840
mediumSTRUCTURE
Filed: Jul 2014

VEHICLE FAILED STATE INSPECTION DUE TO RUSTED FRAME. WITH THE EXCEPTION OF RUST ON THE BUMPERS (WHICH IS ALSO A COMMON PROBLEM FOR THIS GENERATION 4RUNNER) THE REST OF THE VEHICLE IS IN EXCELLENT SHAPE AND MECHANICALLY VERY RELIABLE. INSPECTION STATION SUGGESTED THAT I CONTACT TOYOTA SINCE THEY WERE AWARE OF RECALLS FOR RUSTED FRAMES ON OTHER TOYOTA TRUCKS (TACOMA, SEQUOIA FOR EXAMPLE.) TOYOTA STATED THAT THERE ARE NO RECALLS FOR 4RUNNERS BUT OFFERED A $500 CUSTOMER LOYALTY REBATE IF I WERE TO PURCHASE A NEW OR CERTIFIED USED TOYOTA VEHICLE. I BELIEVE THIS IS A POTENTIAL SAFETY ISSUE SINCE THE RUSTED FRAME PROBLEM WOULD ONLY BE IDENTIFIED BY A VERY THOROUGH INSPECTION OF THE UNDERBODY OF THE TRUCK. IT IS POSSIBLE THAT THERE ARE MANY OTHER 4RUNNERS OF THIS GENERATION THAT ARE ON THE ROAD WITH AN UNDIAGNOSED RUSTED FRAME PROBLEM. *TR

NHTSA #: 10609457
mediumSTRUCTURE
Filed: Jul 2014

TOOK VEHICLE TO LOCAL TOYOTA DEALERSHIP FOR SAFETY AND MECHANICAL INSPECTION AFTER PURCHASING USED; MECHANIC NOTES THAT FRAME IS RUSTED THROUGH ON PASSENGER SIDE, NEAR LOWER TRAILING ARM BRACKET AND ON DRIVERS SIDE NEAR FUEL TANK SKID PLATE. DAMAGE APPEARS TO HAVE ORIGINATED ON THE INSIDE OF THE FRAME AND HAS EATEN ITS WAY TO THE OUTSIDE. MECHANIC ADVISED THAT VEHICLE MAY NOT BE SAFE TO DRIVE, NO RECALL BY TOYOTA ON 4RUNNERS DESPITE SIMILAR ISSUES WITH SAME YEAR TACOMA. *TR

NHTSA #: 10608337
mediumSTRUCTURE
Filed: Jun 2014

TL* THE CONTACT OWNS A 2001 TOYOTA 4RUNNER. THE CONTACT STATED THAT DURING AN INSPECTION SHE WAS NOTIFIED THAT THE RIGHT SIDE OF THE FRAME COMPLETELY CORRODED. THE VEHICLE WAS TAKEN TO A DEALER. THE TECHNICIAN CONFIRMED THE FAILURE AND STATED THAT THE VEHICLE COULD NOT BE REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE DEFECT. THE APPROXIMATE FAILURE MILEAGE WAS 161,213.

NHTSA #: 10605732
mediumSTRUCTURE
Filed: May 2014

TL* THE CONTACT OWNS A 2001 TOYOTA 4RUNNER. THE CONTACT STATED THAT THE VEHICLE WAS TAKEN TO A LOCAL MECHANIC FOR ROUTINE MAINTENANCE WHEN HE WAS ADVISED THAT THE SUBFRAME WAS SEVERELY CORRODED AND FRACTURED. THE VEHICLE WAS TAKEN TO THE DEALER FOR FURTHER INSPECTION WHERE THEY CONFIRMED THAT THE VEHICLE WAS UNSAFE TO DRIVE. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE FAILURE AND CURRENT MILEAGE WAS 92,000. UPDATED 7/16/14*CN

NHTSA #: 10588303
mediumSTRUCTURE
Filed: Apr 2014

EXTREME RUST ON FRAME AND SURROUNDING COMPONENTS. THE 4RUNNER ONLY HAS 115K MILES ON IT. *TR

NHTSA #: 10577071
mediumSTRUCTURE
Filed: Mar 2014

TL* THE CONTACT OWNS A 2001 TOYOTA 4RUNNER. THE CONTACT STATED THAT THE DEALER FOUND THE SUFRAME CORRODED IN THE FUEL TANK AREA WHILE THE FRONT ROTORS AND BRAKE PADS WERE BEING REPLACED. THE FRAME WAS NOT REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE FAILURE AND CURRENT MILEAGE WAS 112,080.

NHTSA #: 10569406
mediumSTRUCTURE
Filed: Feb 2014

WHEN I TOOK MY VEHICLE TO GET A STATE INSPECTION AT MY TOYOTA DEALERSHIP, THE MECHANIC FOUND A RUST HOLE ON MY FRAME . IT IS LOCATED ON THE PASSENGERS SIDE RIGHT BESIDE THE MUFFLER. THIS VEHICLE IS SERVICED REGULARLY AT THIS DEALERSHIP SINCE IT WAS NEW. THERE ARE FORUMS ON THE INTERNET THAT HAVE MANY PEOPLE THAT HAVE THE SAME PROBLEM THAT I DO. IF THESE FRAMES ARE THIS INFERIOR THEY SHOULD BE RECALLED JUST LIKE THE TACOMA AND TUNDRA. *TR

NHTSA #: 10563600
mediumSTRUCTURE
Filed: Oct 2013

BROUGHT VEHICLE TO TOYOTA DEALER FOR REMOVAL OF SEIZED HARDWARE. TECHNICIAN POINTED OUT RUST SPOT ON FRAME, ROT HAS SPREAD TO WHEEL WELL ON BOTH SIDES OF FRAME AND HAS CONTINUED DOWN TO TRANSMISSION CROSSMEMBER. TECHNICIAN POINTED OUT ROT HAS EATEN THROUGH FRAME ON BOTH SIDES AT REAR CONTROL ARM BRACKET. SPOKE WITH OTHER EARLY 2000'S 4RUNNER OWNERS WHO ALL HAVE ROT IN SAME PLACES. PREVENTATIVE MAINTENANCE PRACTICES HAVE BEEN USED ON THIS VEHICLE SINCE I PURCHASED IT. FRAME HAS NO DRAINAGE HOLES FORWARD OF RUST HOLES IN WHEEL WELLS. CONCERNED FOR OTHER 4RUNNER OWNERS WHO ARE UNAWARE OF RUST SPOTS BY CONTROL ARM BRACKETS. FURTHER RUST ON FRAME IN SAME SPOT ON OTHER VEHICLES COULD RESULT IN SEPARATION OF BRACKET, CONTROL ARM AND REAR AXLE FROM FRAME. *TR

NHTSA #: 10549693
mediumSTRUCTURE
Filed: Sep 2013

TL* THE CONTACT OWNS A 2001 TOYOTA 4RUNNER. THE CONTACT STATED THAT THE FRAME WAS RUSTED. THE VEHICLE WAS TAKEN TO A PRIVATE MECHANIC WHERE THE FAILURE WAS CONFIRMED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS CONTACTED, SEVERAL TIMES. THE FAILURE MILEAGE WAS APPROXIMATELY 200,000. UPDATED 12/20/13*CN THE CONSUMER STATED THE VEHICLE IS ON THE SAME FRAME AS OTHER RECALLED TOYOTA VEHICLES. UPDATED 12/26/13

NHTSA #: 10545334
mediumSTRUCTURE
Filed: Sep 2013

TL* THE CONTACT OWNS A 2001 TOYOTA 4RUNNER. THE CONTACT STATED THAT WHILE HAVING ROUTINE MAINTENANCE PERFORMED ON THE VEHICLE, SHE WAS INFORMED BY AN INDEPENDENT MECHANIC THAT DUE TO THE MASSIVE AMOUNT OF CORROSION TO THE FRAME, THE VEHICLE WAS UNSAFE TO DRIVE. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE VEHICLE WAS NOT REPAIRED. THE FAILURE AND CURRENT MILEAGE WAS 125,000.

NHTSA #: 10542831
mediumSTRUCTURE
Filed: Sep 2013

TL* THE CONTACT OWNS A 2001 TOYOTA 4RUNNER. THE CONTACT STATED THAT HE NOTICED THE MUFFLER MAKING A LOUD NOISE WHEN DRIVING AT VARIOUS SPEEDS. THE CONTACT INSPECTED THE VEHICLE AND FOUND THAT THE REAR SUB FRAME MOUNT AREA WAS CORRODED AND EXHIBITED HOLES. THE MANUFACTURE ADVISED THE CONTACT THAT THE VEHICLE WAS A CANADIAN VEHICLE THEREFORE IT COULD NOT BE REPAIRED IN THE UNITED STATES. THE VEHICLE WAS NOT REPAIRED. THE FAILURE AND CURRENT MILEAGE WAS 229,000.

NHTSA #: 10541992
mediumSTRUCTURE
Filed: Jul 2013

TL* THE CONTACT OWNS A 2001 TOYOTA 4RUNNER. THE CONTACT STATED THAT WHILE HAVING THE VEHICLE INSPECTED, HE WAS ADVISED THAT THE FRAME COMPLETELY RUSTED. THE VEHICLE WAS NOT REPAIRED AND THE MANUFACTURER WAS NOTIFIED. THE APPROXIMATE FAILURE MILEAGE WAS 89,300. *TR

NHTSA #: 10522722
mediumSTRUCTURE
Filed: Jun 2013

FRAME RUSTED THROUGH AT REAR NEAR MUFFLER. BOTTOM OF FRAME SECTION APPROXIMATELY 4" MISSING , INSIDE OF FRAME PERFORATED THROUGH APPROXIMATELY 18". REAR SUPPORT ROD STRUCTURAL INTEGRITY COMPROMISED. VEHICLE WAS PURCHASED NEW FROM LOCAL DEAL (LYNCH TOYOTA, MANCHESTER CT) AND IS ONE OWNER GARAGED AND MAINTAINED. CONTACTED TOYOTA AND LOCAL DEALER. BOTH UNWILLING TO TAKE ANY ACTION. NO RECALL ON THIS VEHICLE. *TR

NHTSA #: 10515146
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Filed: Dec 2012

MY 2001 4RUNNER VEHICLE WILL NOT PASS INSPECTION DUE TO CORROSION, ACTUAL HOLES AND SOFT SPOT, ON THE REAR PART OF THE FRAME IN THE MUFFLER AREA. CONCERNED WITH FAILURE WHEN TOWING 300 LBS TRAILER. NO OTHER ISSUES WITH THE VEHICLE, 112K MILES AND BOUGHT NEW 11 YEARS OLD. ONLY DETECTING THE PROBLEM NOW. SHOULD NOT BE NEEDING TO REPLACE FRAME. COST ESTIMATE $10K, SHOPPING AROUND FOR BETTER PRICING. COST TO REPAIR 40% OF THE ORIGINAL PURCHASE PRICE OR TWICE WHAT THE VEHICLE BOOKS TODAY. CONTACTED TOYOTA AND THEY WILL NOT EVEN DISCLOSE # OF COMPLAINT ON THIS ISSUE. THEIR ONLY COMMENTS IS THERE IS NO RECALL AT THIS TIME. FINDING NUMEROUS PEOPLE EXPERIENCING THE SAME ISSUE. *TR

NHTSA #: 10490369
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Filed: Oct 2012

SEVERELY RUSTY FRAME. MY 4RUNNER ONLY HAS A LITTLE OVER 114K MILES ON IT. IT SHOULDN'T HAVE ANYWHERE NEAR THE AMOUNT OF RUST ON THE FRAME. IT'S EVERYWHERE AND FLAKES OFF TO THE TOUCH. *TR

NHTSA #: 10478187
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Filed: Feb 2012

EXTREME RUST ON MY 4RUNNER'S FRAME. CAN BE SEEN EASILY FROM IN AND OUTSIDE OF VEHICLE. I HAVE MANY PICTURES TO DOCUMENT. THE RECALL ON TOYOTA TACOMA AND TUNDRA SHOULD BE EXPANDED TO INCLUDE 96-02 TOYOTA 4RUNNER. *TR

NHTSA #: 10448635
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Filed: Jan 2012

TL* THE CONTACT OWNS A 2001 TOYOTA 4RUNNER. THE CONTACT STATED HAT THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER FOR AN UNRELATED DEFECT WHEN THE TECHNICIAN DETECTED A HOLE IN THE REAR FRAME AND INFORMED THE CONTACT THAT ENTIRE FRAME WAS COMPLETELY RUSTED. THE VEHICLE WAS DAMAGED BEYOND REPAIR. THE MANUFACTURER WAS NOTIFIED OF THE PROBLEM. THE APPROXIMATE FAILURE MILEAGE WAS 128,000. UPDATED 02/10/12 *BF UPDATED 03/12/12

NHTSA #: 10445222
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Filed: Dec 2011

THE 2001 TOYOTA 4 RUNNER IS RUSTING OUT. MY SON AND I BOTH HAVE CUT OUR SELF ON THE REAR BUMPER. I NEEDED STITCHES FOR MY INJURY. I HAVE A SCAR TO REMIND ME NOT TO PURCHASE ANOTHER TOYOTA. THE RUST GOT SO BAD, I LOST MY BUMPER. WHEN I LOOKED UNDER MY VEHICLE AT THE FRAME, THE ENTIRE BOTTOM OF THE VEHICLE IS RIDDLED W/RUST, INCLUDING THE FRAME. CALLED TOYOTA TO SEE IF I COULD AT LEAST GET A SAFETY INSPECTION OF MY FRAME, THEY TOLD ME THAT MY 01 4RUNNER WAS NOT PART OF ANY RECALL AND ANY INSPECTION WOULD COST ME MONEY. *TR

NHTSA #: 10440399
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Filed: Apr 2011

THE REAR AXEL HOUSING ON OUR 2001 SR5 TOYOTA 4-RUNNER IS RUSTED OUT PRETTY BAD. THE ENTIRE FIRST LAYER OF THIN METAL HAS COMPLETELY FLAKED OFF. IT HAS NOT BEGAN TO LEAK YET, BUT IT IS A MATTER OF TIME UNTIL IT DOES. TOYOTA INDICATED THAT THERE HAS NOT BEEN A RECALL ISSUED ON THIS PART, WHICH I THINK THERE SHOULD BE SINCE IT IS SUCH A COMMON OCCURRENCE WITH 1999 - 2002 TOYOTA 4 RUNNERS. THE ENTIRE VEHICLE IS IN GREAT SHAPE, AND RUNS GREAT - WE COULDN'T BE HAPPIER WITH ITS PERFORMANCE. BUT THE ROTTING REAR AXEL NOT ONLY IS SURPRISING, BUT HAS ME QUITE CONCERNED THAT WE WILL END UP WITH A PRETTY EXPENSIVE REPAIR WITHOUT TOYOTA TAKING RESPONSIBILITY FOR AN OBVIOUSLY DEFECTIVE REAR AXEL HOUSING. IF ANYONE SIMPLY DOES AND INTERNET SEARCH REGARDING THIS PROBLEM - YOU WILL SEE THAT ARE LITERALLY THOUSANDS OF TOYOTA TRUCKS THAT ARE EXPERIENCING THIS PROBLEM WITH THE REAR AXEL HOUSING. *TR

NHTSA #: 10398092
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Filed: Mar 2010

TL*THE CONTACT OWNS A 2001 TOYOTA 4RUNNER. THE CONTACT NOTICE THAT THE FRONT AND REAR BUMPERS WERE COVERED WITH RUST IN MARCH 2007. HE TOOK THE VEHICLE TO THE DEALERSHIP AND THE DEALER TOLD HIM THAT THE ROAD SALT CAUSED THE BUMPER TO RUST. HE CALLED THE MANUFACTURER AND FILED A COMPLAINT WITH A REPRESENTATIVE. THE VEHICLE HAD NOT BEEN REPAIRED AT THE TIME OF THE COMPLAINT. THE CURRENT MILEAGE WAS APPROXIMATELY 66,000. THE FAILURE MILEAGE WAS APPROXIMATELY 40,000. UPDATED 04/12/10.

NHTSA #: 10315234
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Filed: Dec 2009

HELLO, I OWN A 2001 4RUNNER AND THE FRONT AND REAR BUMPERS ARE RUSTING HORRIBLY WITH THE FRONT AND REAR BUMPERS ACTUALLY HAVING AN HOLE ALL THE WAY THROUGH. I HAVE CONTACTED TOYOTA DIRECTLY ON 2 OCCASIONS AND THEY HAVE REFUSED TO DO ANYTHING. I HAVE BEEN PATCHING WITH FIBERGLASS BUT THE RUST CONTINUES. I LIVE IN MASSACHUSETTS AND EVERY 2001 4RUNNER THAT I SEE ON THE ROAD HAS THE SAME PROBLEM. THIS IS A SAFETY ISSUE SINCE THE RUST AFFECTS THE INTEGRITY OF THE FUNCTION OF THE BUMPERS IN THE EVENT OF A COLLISION. ALSO, I CANNOT GET AN INSPECTION STICKER WITH HOLES IN THE BUMPERS. THE COST TO REPLACE THEM IS WELL OVER $1,300. FROM A VISUAL INSPECTION, LARGE CHUNKS WILL CONTINUE TO RUST OFF THE INSIDE OF THE BUMPERS DURING THE NEXT 6 MONTHS. *TR

NHTSA #: 10295802
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Filed: May 2009

THE FRONT AND REAR BUMPERS ON MY 2001 TOYOTA 4RUNNDER ARE COMPLETELY RUSTED OUT (FROM THE INSIDE OUT). THE REST OF THE VEHICLE IS IN EXCELLENT CONDITION. NEVER BEEN IN AN ACCIDENT. ANYONE WALKING BY THE VEHICLE COULD ACCIDENTALLY BRUSH BY THE BUMPERS AND GET CUT FROM THE JAGGED EDGES; ALSO NOT SURE WHAT GOOD THEY WOULD DO IN CASE OF ANY IMPACT. *TR

NHTSA #: 10267604
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Filed: Nov 2005

REAR BUMPER RUSTING THROUGH FROM THE INSIDE OUT. DEALER SAYS THE RESULT OF POOR WELDS ON THE BUMPER BRACKETS. VEHICLE HAS 5 YEAR RUST THROUGH WARRANTY THAT DEALER AND COMPANY WILL NOT HONOR ON THE BUMPER, ONLY ON SHEET METAL. *NM

NHTSA #: 10142074
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Filed: Sep 2003

WHILE TRAVELING ON THE HIGHWAY WITH THE DRIVER AND PASSENGER'S SIDE WINDOWS DOWN, THE WAS A VIBRATION COMING FROM THE REAR OF THE VEHICLE. *AK THE VEHICLE EXPERIENCED WIND TURBULENCE FAILURES WHEN DRIVEN 30 MPH WITH ALL THE WINDOWS CLOSED, THEN SUDDENLY THE REAR PASSENGER WINDOW WAS OPENED AND A LOUD SOUND OCCURRED. THIS CAUSED EAR DAMAGES AND DIZZINESS TO THE DRIVER AND PASSENGERS. *SCC *JB

NHTSA #: 10024159

Other 2001 Toyota 4runner Issues