MyCarTSB

2005 Toyota 4runner Suspension Problems

62 owner-reported suspension complaints from NHTSA data

62
Complaints
1
Crashes
Jan 2020Dec 2023
Date Range

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

Owner Complaints (62)

criticalSUSPENSION,UNKNOWN OR OTHER
Filed: May 2025

Your 4Runner's frame has extensive rust, holes, and cracks throughout, creating a structural integrity concern. While a Toyota dealership has said it's currently safe to drive, the frame damage may eventually compromise the vehicle's ability to stay together, potentially causing loss of control at highway speeds. A dealership inspection can confirm the extent of the damage. Addressing this issue may require professional frame inspection, rust removal, welding repairs, or frame replacement.

NHTSA #: 11663625
highSUSPENSION
Filed: Dec 2023

Your 4Runner's frame has developed significant rust with actual holes forming in the metal structure. The frame damage is extensive enough that it's considered unrepairable at this point. Addressing this level of frame corrosion typically requires professional structural assessment and may involve frame replacement or welding repair work by a specialist.

NHTSA #: 11562313
highSUSPENSION,STRUCTURE,UNKNOWN OR OTHER
Filed: Nov 2023

Your vehicle's frame is showing rust and corrosion, similar to a known issue that affected 2005 Tacomas from the same year. Toyota replaced frames for affected Tacomas, but not for 4Runners with the same problem. Many other 4th generation 4Runners appear to be experiencing similar rust issues. Addressing frame rust typically involves professional inspection, rust treatment, and potentially frame repair or replacement depending on severity.

NHTSA #: 11553471
highSUSPENSION,STRUCTURE
Filed: May 2023

Your 4Runner's sub-frame (the structural support underneath your vehicle) has developed severe corrosion. This was discovered during a service visit at an independent mechanic when the vehicle had about 166,000 miles. A corroded sub-frame can compromise your vehicle's structural integrity and safety. Repairing this will likely involve having the corroded sub-frame inspected, treated, or replaced depending on the extent of the damage.

NHTSA #: 11520258
mediumSUSPENSION
Filed: Sep 2022

The frame on both sides of the vehicle in the front, where it connects under the radiator crossbar has rusted through.Not feeling to safe about this. also the transmission cooling lines are also looking thin. The dealership I have maint. done at informed me of this condition. Can send pictures if needed.

NHTSA #: 11484406
mediumSUSPENSION,STRUCTURE
Filed: Sep 2022

My frame has rotted through, causing the rear bump stops to fall off, putting excessive wear on both frame and suspension components. In parts of the frame, it has rotted all the way around and caused a loss in structural integrity. Worst of all, there is a hole near the rear most strap holding the gas tank to the chassis, which is a risk to not only me and my pregnant wife but others driving on the road around me if it where to fall off. Looking at the body, there is no rust or corrosion. The same goes for the engine bay, the rust is entirely located on the frame. Mechanically, the vehicle is in excellent shape. It has now got to the point it will no longer pass a NYS inspection.

NHTSA #: 11483876
mediumSUSPENSION
Filed: Oct 2021

Vehicle’s frame and suspension is showing major rust prematurely forming from the inside-out of the frame causing visible weakness in the structure of the frame that could cause engine or other suspension parts to fall off the frame of the car due to improper treatment of the frame. If I were to get in a car accident I don’t see the frame holding it’s structure. I would I highly suggest to have a safety recall done with frames with such damage.

NHTSA #: 11437140
mediumSUSPENSION,STRUCTURE
Filed: Oct 2021

Brought the car in for an alignment and I was told they couldn’t do it because of all the damage to the frame from rust, parts of the frame are not even there anymore, the front row hooks are gone, they said that all this damage ca impact the handle of the car and that it can’t be properly aligned and possibly won’t pass inspection.

NHTSA #: 11435632
mediumSUSPENSION,STRUCTURE
Filed: Aug 2021

Frame and rear differential rust- extreme

NHTSA #: 11429160
mediumSUSPENSION
Filed: Aug 2021

The contact owns a 2005 Toyota 4Runner. The contact stated that while the vehicle was receiving maintenance work from an independent mechanic, the mechanic informed the contact that the sub frame was very rusted. The mechanic was unable to complete the maintenance work. The vehicle was taken to a dealer where they provided the contact an estimate for the repair. The vehicle was not repaired. The manufacturer was not notified of the failure. The approximate failure mileage was 142,500.

NHTSA #: 11427564
mediumSUSPENSION
Filed: Jul 2021

The contact owns a 2005 Toyota 4Runner. The contact stated that upon taking the vehicle to an independent mechanic, she was informed that significant corrosion had developed on the front end of the undercarriage. The contact was then referred by the independent mechanic to the dealer where she was informed that while was rust found on the undercarriage of the vehicle, the vehicle was safe to operate and no repairs were needed. A month after the dealer inspection, the contact stated that an abnormal sound was coming from her brake pedal upon depression without warning. Once the contact made it home, she had the vehicle towed to an independent mechanic. The mechanic initially informed her that the vehicle was a total loss however, he and another mechanic were able to remove a large portion of the rust and replaced the brake pads, rotors, power steering line, hose, and brake pads. Recently, contact stated that her son had driven the vehicle and that the vehicle began to exhibit the same brake failure that had been replaced by the mechanic. The manufacturer was notified of the failure but offered no assistance. The vehicle was not repaired. The failure mileage was approximately 93,000.

NHTSA #: 11425531
mediumSUSPENSION,FUEL/PROPULSION SYSTEM
Filed: Jul 2021

Extensive, rapidly spreading rust throughout the vehicle's frame and fuel tank supports leaving little or nothing holding the fuel tank or areas of the suspension together. Vehicle cannot be safely placed on a lift for service because of thin metal in the bottom of the frame. .

NHTSA #: 11423459
mediumSUSPENSION,STRUCTURE
Filed: Mar 2021

TL* THE CONTACT OWNS A 2005 TOYOTA 4RUNNER. THE CONTACT STATED THAT UPON TAKING THE VEHICLE TO A-1 TOYOTA (50 AMITY RD, NEW HAVEN, CT 06515) SIGNIFICANT RUST WAS DISCOVERED ON THE SUBFRAME OF THE VEHICLE. THE MECHANIC FOUND A HOLE IN THE RADIATOR SUPPORT AND ANOTHER HOLE ON THE DRIVER SIDE FRAME RAIL. THE CONTACT WAS INFORMED THAT THE VEHICLE WAS SAFE TO DRIVE HOWEVER, THE PROLONGED RUST BUILD UP COULD LEAD TO A SEVERE MECHANICAL FAILURE. THE CONTACT WAS INFORMED THAT THERE WERE NO RECALLS ON THE VIN. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE BUT OFFERED NO FURTHER ASSISTANCE. THE FAILURE MILEAGE WAS UNKNOWN.

NHTSA #: 11403514
mediumSUSPENSION,UNKNOWN OR OTHER
Filed: Nov 2020

NOTHING HAPPENED YET BUT FOUND UPON CHECKING THAT THE REAR DIFFERENTIAL UPPER CONTROL ARM THAT IS ATTACHED TO THE FRAME IS RUSTED THROUGH. I AM AFRAID IT WILL DETACH WHILE DRIVING AND CAN CAUSE AN ACCIDENT. I HAVE REMOVED THE FLAKY METAL MYSELF IN THE SUMMER OF 2020 AND PAINTED IT TO AVOID FURTHER RUSTING. THE CROSSBAR IN THE FRONT THAT IS SUPPORTING THE RADIATOR IS RUSTED THROUGH AS WELL. THE METAL THAT IS HOLDING THE TANK IS GONE TOO.

NHTSA #: 11376362
mediumSUSPENSION,STRUCTURE
Filed: Oct 2020

FRAME IS RUSTED THRU ON BOTH FRONT SIDES WHERE THE CONTROL ARMS ATTACH

NHTSA #: 11363032
mediumSUSPENSION,FUEL SYSTEM, GASOLINE,STRUCTURE
Filed: Sep 2020

TL* THE CONTACT OWNS A 2005 TOYOTA 4RUNNER. THE CONTACT STATED THAT YEARS AGO, AN INDEPENDENT MECHANIC DISCOVERED SEVERE CORROSION ON THE UNDERCARRIAGE OF THE VEHICLE. THE CONTACT RECENTLY HAD A FUEL LEAK FAILURE WHICH SHE LINKED TO THE CORROSION ON THE VEHICLE. NEITHER THE DEALER NOR THE MANUFACTURER HAD BEEN NOTIFIED OF THE FAILURE. THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS UNKNOWN. *LN*JB

NHTSA #: 11354947
mediumSUSPENSION
Filed: Aug 2020

FRONT FRAME RUSTED BEYOND REPAIR.

NHTSA #: 11350092
mediumSUSPENSION
Filed: Aug 2020

THE FRAME IS RUSTING AWAY

NHTSA #: 11349832
mediumSUSPENSION
Filed: Jul 2020

I HAVE A 2005 TOYOTA 4RUNNER PURCHASED NEW GARAGED KEPT WITH 66200 MILES WITH EXCESSIVE FRAME AND UNDERBODY RUST. I AM CONCERNED WITHOUT A FRAME REPLACEMENT FROM TOYOTA I WILL NOT BE ABLE TO DRIVE IT AS THE SAFETY CRASH STANDARDS NOT TO BE ACCEPTABLE AS NEW OR FRAME TO BRAKE AND CAUSE AN ACCIDENT.

NHTSA #: 11339560
mediumSUSPENSION,STRUCTURE,UNKNOWN OR OTHER
Filed: Apr 2020

HI, I OWN A 2005 4RUNNER AND I AM CONCERNED ABOUT THE HEAVY AMOUNT OF RUSTING ON THE FRAME. THE FRAME IS RUSTY WHICH IS CAUSING HEAVY FLAKING OF THE AFFECTED MATERIAL. THE BODY OF THE VEHICLE IS PRISTINE BUT I FEAR THAT THE PREMATURE RUSTING OF THE FRAME WILL AFFECT THE ABILITY TO SAFELY DRIVE MY 4RUNNER IN THE FUTURE. I AM A SPECIAL EDUCATION TEACHER WITH TWO YOUNG DAUGHTERS AND DON'T HAVE THE INCOME TO GO OUT AND REPLACE THE FRAME OR BUY A NEW VEHICLE. THIS 4RUNNER IS THE ONLY VEHICLE I OWN AND IS MY DAILY DRIVER. MY STUDENTS AND THEIR GUARDIANS DEPEND ON ME TO ARRIVE SAFELY TO SCHOOL EVERYDAY SO THERE IS CONSISTENCY IN MY STUDENTS' LIVES. I HAVE SEEN MANY 4RUNNERS IN THIS AGE RANGE SUFFER FROM THIS SAME CORROSION. I AM CONCERNED THAT MY FAMILY WILL BE INJURED IN A MINOR ACCIDENT OR THE VEHICLE'S SAFETY MECHANISMS FAILING BECAUSE OF FRAME DAMAGE. I AM ALSO CONCERNED THAT I WILL LOSE MY ONLY MEANS OF TRANSPORTING MYSELF TO WORK. I AM A HUGE FAN OF TOYOTA, ESPECIALLY 4RUNNERS, AND WANT TO KEEP MINE AROUND FOR A LONG TIME. KEEPING TOYOTA VEHICLES AROUND FOR A LONG TIME IS WHAT THE COMPANY WAS BUILT UPON.

NHTSA #: 11321440
mediumSUSPENSION,STRUCTURE
Filed: Jan 2020

EXCESS FRAME RUST. MECHANIC STATES FRAME HAS SEVERE RUST ALL OVER THE ENTIRE FRAME AND IS IN EMINENT DANGER OF COMPLETELY RUSTING THROUGH. MAJOR FRAME REPAIR OR REPLACEMENT IS NEEDED.

NHTSA #: 11306267
mediumSUSPENSION
Filed: Jan 2020

THE FRAME IS VERY RUSTY AND LOOKS LIKE IT'S GOING TO BREAK SOON. THIS IS THE SAME FRAME AS A TACOMA PICKUP

NHTSA #: 11292475
mediumSUSPENSION,STRUCTURE
Filed: Dec 2019

TL* THE CONTACT OWNS A 2005 TOYOTA 4RUNNER. WHILE DRIVING 45 MPH, THE REAR OF THE VEHICLE WAS MOVING. THE CONTACT STATED THAT THE SWAY BAR FRACTURED AND DETACHED FROM THE FRAME. IN ADDITION, THE TRACTION CONTROL AND TPMS WARNING INDICATORS WERE ILLUMINATED. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE DEALER AND MANUFACTURER WERE NOT CONTACTED. THE FAILURE MILEAGE WAS 125,000.

NHTSA #: 11289695
mediumSUSPENSION,STRUCTURE
Filed: Nov 2019

MY VEHICLE FAILED INSPECTION DUE TO A HOLE IN THE FRAME. MY VEHICLE HAS THE SAME FRAME AS THE TACOMA TRUCKS THAT HAVE FRAME ROT AND HAVE ALREADY BEEN RECALLED.

NHTSA #: 11280721
mediumSUSPENSION,STRUCTURE
Filed: Sep 2019

TL* THE CONTACT OWNS A 2005 TOYOTA 4RUNNER. WHILE DRIVING AT AN UNKNOWN SPEED, THE CONTACT HEARD A GRINDING METAL NOISE. THE CONTACT COASTED THE VEHICLE OVER TO THE SIDE OF THE ROAD AND NOTICED THAT THE ENTIRE FRAME WAS CORRODED. THE CONTACT STATED THAT THE FRONT BUMPER FRAME RUSTED OUT AND THE REAR PASSENGER SIDE FRAME SUSPENSION MOUNT WAS CORRODED THROUGH AND DETACHED. THE CONTACT STATED THAT THE REAR DRIVER'S SIDE FRAME SUSPENSION MOUNT WAS HEAVILY CORRODED, BUT WAS OK FOR THE TIME BEING. THE VEHICLE WAS NOT TAKEN TO A DEALER OR AN INDEPENDENT MECHANIC FOR DIAGNOSTIC TESTING. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 183,000.

NHTSA #: 11254890
mediumSUSPENSION
Filed: Aug 2019

FRAME BROKE LOWER CONTROL ARM CROSS MEMBER LEFT SIDE NO STEERING HALF PULLED OUT OF TRANSMISSION.

NHTSA #: 11242600
mediumSUSPENSION,STRUCTURE
Filed: Apr 2019

THE FRAM IS RUSTED AND NO TIME KNOWN WILL IT GIVE OUT N CAUSE SERIOUS ACCIDENT.

NHTSA #: 11196668
mediumSUSPENSION,AIR BAGS,UNKNOWN OR OTHER
Filed: Apr 2019

THE FRAME ON MY 2005 TOYOTA 4RUNNER IS SEVERELY RUSTED. I HAVE HAD MULTIPLE PIECES FALL OFF MY SUV, SOME WHILE DRIVING. THIS INCLUDES THE FRONT SKID PLATE, TRANSMISSION LINES, AND OTHER SMALL COMPONENTS. THE FRAME ON MY SUV IS COMING APART. RATHER LARGE PIECES ARE 'FLAKING' OFF. IT IS PLAIN TO SEE WHERE THE METAL IS SEPARATING. I RECENTLY DISCOVERED THAT THE FRONT IMPACT SENSORS HAVE RUSTED LOOSE OF THE FRAME AND ARE NOW DANGLING FREE. THIS LEAVES MY SUV SUSCEPTIBLE TO THE AIRBAGS NOT INFLATING DURING A FRONT-END CRASH. THE ABOVE HAS BEEN OCCURRING OVER THE LAST FEW YEARS. I HAVE OPENED CASE #1707170870 WITH TOYOTA, BUT THEY HAVE TOLD ME THAT THERE IS NO REMEDY FOR MY VEHICLE.

NHTSA #: 11196507
mediumSUSPENSION,UNKNOWN OR OTHER
Filed: Apr 2019

EXHAUST SMELL ENTERING CABIN, GETS WORSE WHEN ACCELERATING ON RAMP. EVEN WITH RECIRCULATION OF AIRFLOW HEAT AND OR AIR CONDITIONER STILL SMELLS BAD. I HAVE TO DRIVE WITH WINDOWS OPEN EVEN IN WINTER. ALSO RUST ALL OVER SUSPENSION, UNDERCARRIAGE. PLEASE TELL IF THIS IS A COMMON PROBLEM AND SAFETY RECALL. THIS STARTED SHORTLY AFTER PURCHASING THE TRUCK IN 2017 AND HAS GOTTEN WORSE SINCE. THE MUFFLER WAS REPLACED ALREADY.

NHTSA #: 11196100
mediumSUSPENSION
Filed: Apr 2019

TAKATA RECALL, I TOOK MY 2005 TOYOTA 4RUNNER SR5 TO A TOYOTA DEALERSHIP TODAY TO GET A TIRE ROTATION. THEY TOLD ME MY FRAME WAS TOO RUSTED OUT TO LIFT UP FOR FEAR OF HARMING MY CAR. I HAD NEW TIRES PUT ON AT THE SAME DEALERSHIP IN OCTOBER AND THEN NEW TRD WHEELS INSTALLED AT ANOTHER DEALERSHIP WHERE NOT A SINGLE MECHANIC MENTIONED RUST ON MY FRAME. APPARENTLY IT'S MY REAR PASSENGER SIDE THAT HAS IT THE WORST.

NHTSA #: 11194265
mediumSUSPENSION,STRUCTURE
Filed: Apr 2019

I TOOK MY 4-RUNNER TO MY MECHANIC ON APRIL 1, 2019 TO HAVE THE BRAKES CHECKED AND A CV BOOT REPAIRED. MY MECHANIC CALLED ME THE NEXT DAY AND INFORMED ME THAT THE MAIN SUPPORT BEAM OF THE FRAME ON THE PASSENGER SIDE WAS RUSTED OUT AND VIRTUALLY MISSING ON 3 OF THE 4 SIDES OF THE BEAM. HE TOLD ME THE VEHICLE COULD BREAK IN HALF IF I HIT A BUMP ON THE ROAD.

NHTSA #: 11194071
mediumSUSPENSION
Filed: Mar 2019

INFERIOR, STEEL, RUSTED FRAME AND SUSPENSION, TOO DANGEROUS TO DRIVE. CONSUMER STATED MY TRUCK IS BACK ON SHOP WITH STETLER DODGE THEY ARE RIPPING IT APART.*JB

NHTSA #: 11191057
mediumSUSPENSION,STRUCTURE,UNKNOWN OR OTHER
Filed: Feb 2019

THERE'S EXCESSIVE RUSTING OF THE CHASSIS, AXLE, DIFFERENTIAL AND OTHER COMPONENTS UNDER THE VEHICLE. I'M THE ORIGINAL OWNER AND OBSERVED RUST FORMATION WITHIN THE FIRST YEAR OF OWNERSHIP. THE SUV HAS ONLY 84K MILES AND IS GARAGED MOST OF THE TIME. I HAVE BEEN USING RUST INHIBITORS TO SLOW THE PROCESS.

NHTSA #: 11180039
mediumSUSPENSION,POWER TRAIN,STRUCTURE,UNKNOWN OR OTHER
Filed: Feb 2019

2005 TOYOTA 4RUNNER SR5 WAS TAKEN INTO A CERTIFIED TOYOTA MECHANIC FOR INSPECTION AND THE MECHANIC SHOWED ME THE UNDERCARRIAGE OF THE VEHICLE, NAMELY THE FRAME AND OTHER ASSOCIATED PARTS. HE WARNED THAT IT WOULD BE DIFFICULT TO PERFORM MAINTENANCE ON THE VEHICLE IF THE FRAME IS ROTTED THROUGH. THE VEHICLE WAS PUT ON A LIFT FOR INSPECTION.

NHTSA #: 11180197
mediumSUSPENSION
Filed: Jan 2019

THE FRAME IS RUSTED OUT AT THE REAR AND AT THE RADIATOR SUPPORT AND AT THE REAR STABILIZER ON BOTH SIDES AND THE REAR BUMPER IS RUSTED INTO ON BOTH SIDES OF THE FRAME IN MY OPINION IT IS UNSAFE TO USE. MY WIFE HAD A CLOSE CALL WHEN THE REAR STABILIZER BROKE THE FROM THE FRAME ON BOTH SIDES

NHTSA #: 11171464
mediumSUSPENSION
Filed: Jan 2019

TL* THE CONTACT OWNS A 2005 TOYOTA 4RUNNER. THE CONTACT STATED THAT THERE WAS EXTENSIVE RUST AND CORROSION ON THE FRONT AND REAR SUSPENSION AS WELL AS THE FRAME OF THE VEHICLE. LANGWAY TOYOTA OF NEWPORT (285 E MAIN RD, MIDDLETOWN, RI 02842, (401) 619-5400) DIAGNOSED THAT THE FRAME AND REAR AXLE MOUNT WERE FAULTY, AND FURTHER EXTENSIVE SERVICING WAS REQUIRED. THE DEALER WAS NOT AUTHORIZED TO REPAIR THE VEHICLE. THE VEHICLE WAS INSPECTED AND DIAGNOSED BY AN INDEPENDENT MECHANIC. THE VEHICLE WAS NOT INCLUDED IN NHTSA ACTION NUMBER: DP18002 (STRUCTURE). THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE VIN WAS NOT AVAILABLE. THE APPROXIMATE FAILURE MILEAGE WAS 143,000.

NHTSA #: 11166348
mediumSUSPENSION,UNKNOWN OR OTHER
Filed: Jan 2019

2005 TOYOTA 4RUNNER 156K MILES WITH SUBSTANTIAL RUST AND CORROSION TO FRAME TO THE POINT WHERE MECHANIC CAN NO LONGER SERVICE THE VEHICLE.

NHTSA #: 11165909
mediumSUSPENSION
Filed: Dec 2018

SUSPENSION. VEHICLE USED IN THE NE US--MA. VEHICLE IS UNSTABLE AT HIGHWAY SPEEDS. WANDERS. IMPOSSIBLE TO KEEP STEADY. HEAVY RATTLE IN SUSPENSION AT ALL TIMES (FIRST NOTED IN 2015), EXCEPT ON VERY SMOOTH PAVEMENT. SIGNIFICANT RUSTING NOTED ON REPAIRS. MAY NOT PASS SAFETY INSPECTION. NO BODY RUST. MILEAGE LESS THAN 150K.

NHTSA #: 11161366
mediumSUSPENSION
Filed: Nov 2018

FRAME AND SUSPENSION MOUNTING POINTS RUSTED OUT CAUSING A SUSPENSION MOUNTING BRACKET FAILURE.VEHICLE WAS PULLING AWAY FROM STOP.

NHTSA #: 11153999
mediumSUSPENSION,STRUCTURE,SERVICE BRAKES
Filed: Nov 2018

TOYOTA DEALER FAILED SAFETY INSPECTION DUE TO REAR SUSPENSION ARM RUSTED OFF AND A HOLE RUSTED THROUGH FRAME. ONLY HAS 124,000 MILES. TOYOTA SAID THAT VEHICLE IS UNSAFE TO DRIVE AND REAR END MAY LIFT DURING A HARD STOP. REAR BRAKE LINES ARE ALSO RUSTED OUT.

NHTSA #: 11152906
mediumSUSPENSION,STRUCTURE
CrashFiled: Nov 2018

MY REAR FRAME ROTTED OUT CAUSING MY CONTROL ARM TO BREAK OFF. THE VEHICLE WAS EXTREMELY HARD TO CONTROL CAUSING A ROLLOVER ACCIDENT.

NHTSA #: 11152991
mediumSUSPENSION,UNKNOWN OR OTHER
Filed: Oct 2018

THE FRAME RUSTED THROUGH AT THE CONNECTING POINT OF THE REAR PASSENGER SIDE TRAILING ARM. MUCH OF THE FRAME IN THIS AREA IS SEVERELY ROTTED BY RUST. I NOTICED THAT THE VEHICLE WAS NOT TRACKING DOWN THE ROAD VERY WELL, WHICH WAS ABNORMAL. UPON RETURNING HOME I FOUND THE PROBLEM OF THE RUSTED FRAME.

NHTSA #: 11142299
mediumSUSPENSION,POWER TRAIN,STRUCTURE
Filed: Oct 2018

THE REAR AXLE RUSTED SO BADLY THAT IT STARTED FLAKING APART. THE FRAME IS RUSTED SEVERELY IN THE AREAS WHERE THE REAR SUSPENSION COMPONENTS ATTACH. THE GAS TANK SKID PLATE RUSTED UNTIL IT BEGAN TO FALL OFF WHILE DRIVING DOWN THE ROAD AND ALL OF THE AREAS WHERE IT WAS BOLTED TO THE FRAME COMPLETELY RUSTED OUT. THE EXHAUST ALSO RUSTED THROUGH BEHIND THE MUFFLER CAUSING IT TO FALL OFF WHILE DRIVING DOWN THE ROAD. THERE ARE HOLES IN MULTIPLE AREAS OF THE FRAME. I HAD TO GRIND,CHIP, AND WIRE BRUSH THE FRAME WITH THE VEHICLE ON JACK STANDS IN ORDER TO REPAINT EVERYTHING AND KEEP MY VEHICLE GOING. THIS TOOK OVER 100 HOURS OF LABOR JUST TO COMPETE. I ALSO HAD TO REPLACE THE EXHAUST AND THE GAS TANK SKID PLATE. ALL OF THE BOLTS FOR THE SKID PLATES ON THE BOTTOM OF THE VEHICLE WERE COMPLETELY RUSTED THROUGH AND COULD NOT BE REMOVED WITHOUT FALLING APART AND LEAVING HALF THE BOLT IN THE FRAME. THE XREAS SUSPENSION SYSTEM WHICH RUNS HYDRAULIC LINES AROUND THE FRAME ALSO RUSTED APART AND LEAKED FLUID ALL OVER EVERYTHING. THE BOLTS WERE ALL HEAVILY RUSTED AND COULD NOT BE REMOVED TO GET THE LINES OFF THE FRAME. THE FRAME ON THIS VEHICLE WAS NOT ADEQUATELY COATED TO PREVENT IT FROM RUSTING. THIS NEEDED TO BE DONE WITH APPROXIMATELY 100,000 MILES ON THE VEHICLE.

NHTSA #: 11141370
mediumSUSPENSION
Filed: Aug 2018

TOO MUCH RUST ON THE FRAME OF MY CAR ONLY HAVE 63000 MILES AND ALWAYS GARAGED

NHTSA #: 11121635
mediumSUSPENSION,STRUCTURE
Filed: Aug 2018

UNDER BODY RUST TOOK TO COSTCO TO REPLACE TIRES - THEY SAY SIGNIFICANT RUST ON LEFT SIDE. TOOL TO JIFFY LUBE FOR OIL CHANGE ONE WEEK LATER - THEY SAY SIGNIFICANT RUST AND CANNOT REMOVE REAR DIFFERENTIAL TO REPLACE FLUID DUE TO RUSTED BOLT.

NHTSA #: 11120819
mediumSUSPENSION,UNKNOWN OR OTHER
Filed: Aug 2018

PURCHASED 2005 TOYOTA 4RUNNER IN 2012 WITH 58K MILES. ALWAYS WASHED UNDERCARRIAGE. MECHANIC BEGAN PATCHING RUST ON FRAME 2011. ITS BEYOND REPAIR NOW WITH 128K MILES. FRAME IS COMPLETELY DANGEROUS

NHTSA #: 11118868
mediumSUSPENSION
Filed: Mar 2018

3/4 OF THE UNDERNEATH OF MY 2005 TOYOTA RUSTED OUT AND RELEASED THE BAR THAT HELD MY TIRE IN PLACE. I DROVE 80 HIGHWAY MILES NOT KNOWING THAT THE TIRE WAS NOT SUPPORTED.

NHTSA #: 11080041
mediumSUSPENSION
Filed: Jan 2018

MY MECHANIC FOUND SIGNIFICANT ROTTING DAMAGE ON THE CHASSIS OF MY 2005 TOYOTA 4RUNNER. HE ADVISED ME NOT TO DRIVE THE VEHICLE AS THE WHEEL COULD BREAK OFF. I CONTACTED TOYOTA, BUT THEY TOLD ME THERE WERE NO RECALLS ON THE VEHICLE, EVEN THOUGH CHASSIS ROTTING HAS BEEN A PROBLEM WITH THEIR OLDER VEHICLES.

NHTSA #: 11066006
mediumSUSPENSION,STRUCTURE
Filed: Dec 2017

2005 TOYOTA 4RUNNER STRUCTURAL FRAME RAPID OXIDATION TO STRUCTURE CAUSING LEFT FRONT CONTROL ARM TO FRAME (AS WELL AS FRAME ITSELF) TO BREAK WHILE IN MOTION AT SLOW SPEED LEAVING DRIVEWAY. I HAVE CONTACTED TOYOTA CASE# 1712112893 TO ASK WHY THERE IS NO BUYBACK PROGRAM ON FRAMES THAT THEY PRODUCED IN 2004 THAT WERE FOUND DEFECTIVE IN TACOMA'S/4RUNNERS THAT WERE ALSO USED FOR THEIR 2005 MODEL PRODUCTION 4RUNNERS. TOYOTA REP TOLD MYSELF THAT NO CAMPAIGNS WOULD EXIST UNLESS OTHERWISE TOLD SO (OR PERHAPS INVESTIGATED FOR THEIR PRIOR ACKNOWLEDGED DEFECTIVE FRAMES USED IN PREVIOUS MODEL YEARS). THOUGH I AM LUCKY THAT THIS OCCURRED AT SLOW SPEED I DON'T KNOW HOW MANY OTHER AMERICANS MAY FACE MY SITUATION WHILE AT 60-70MPH ON THE HIGHWAY WITH THEIR FAMILIES WHOM TRUST TOYOTA FOR THEIR SAFETY AND PRODUCT RELIABILITY THAT END IN ULTIMATE TRAGEDY. I'VE INCLUDED PHOTOS AS WELL AS A CLEAN CARFAX REPORT TO SHOW NO PRIOR INCIDENTS. THANK YOU.

NHTSA #: 11054205
mediumSUSPENSION,STRUCTURE
Filed: Oct 2017

FRAME HAS RUSTED SIMILAR TO TACOMA AND SEQOUIYA RECALLS AND DO NOT SEE WHY THEY HAVE NOT BEEN RECALLED.

NHTSA #: 11032663
mediumSUSPENSION,UNKNOWN OR OTHER
Filed: Dec 2016

FRAME RUST - PROBLEM IS THE SAME AS WHAT HAS HAPPENED TO SAME YEAR TOYOTA TACOMA PICKUPS. THESE VEHICLES SHOULD ALSO BE RECALLED AND HAVE THE SAME FIX APPLIED TO THEM AS WAS APPLIED TO THE TACOMA PICKUP. PURCHASED VEHICLE USED IN OCTOBER AND HAD SHOP PUT IT UP ON A LIFT 2 MONTHS LATER FOR ROUTINE MAINTENANCE. THEY SAID FRAME RUSTED AND UNSAFE TO DRIVE.

NHTSA #: 10936133
mediumSUSPENSION,POWER TRAIN,STRUCTURE
Filed: Nov 2016

EXCESIVE RUST UNDER BODY. EXHAUST SYSTEM AND FRAME.

NHTSA #: 10926250
mediumSUSPENSION,STRUCTURE,UNKNOWN OR OTHER
Filed: Sep 2015

THERE WAS NO "FRAME ROTTING" SELECTION SO I JUST CHOSE WHAT I THINK IS AFFECTED. MAJOR SCALING ON THE INSIDE. OUTSIDE LOOKS PERFECT. WELL, IT SEEMS THAT THE INSIDE ROTTED SO BAD THAT MY INNER FRAME RAIL ON THE PASSENGER SIDE NEAR THE REAR TRACK ARM HAD ALMOST ROTTED THROUGH. IT IS SOFT LIKE A SPONGE, BUT YET THE FACTORY TOYOTA FRAME PAINT HELD IT TOGETHER. POKING IT WITH MY FINGER AND IT ALL CRUMBLED REVEALING QUITE A FEW HOLES. HOOD ALSO HAS A LOT OF LITTLE RUSTED PARTS. THIS DIDN'T HAPPEN BECAUSE OF NEGLIGENCE OF MY PART. I TAKE GOOD CARE OF MY CARS AND NEVER HAD TROUBLES LIKE THESE WITH ANY OTHER CAR BRANDS.

NHTSA #: 10776570
mediumSUSPENSION,POWER TRAIN,STRUCTURE
Filed: Jun 2015

LOW MILEAGE CAR AND PARTS OF THE FRAME ARE FALLING A PART. DEALER REFUSES TO SERVICE CAR AS IT IS UNSAFE. TOYOTA SAYS THEY HAVE NO PROBLEMS WITH THE 4RUNNERS RUSTING JUST THERE TRUCKS AT THIS TIME...?

NHTSA #: 10726194
mediumSUSPENSION,STRUCTURE,SERVICE BRAKES
Filed: Sep 2014

I OWN A 2005 TOYOTA 4RUNNER. THE FRAME IS RUSTING SO SEVERELY THAT IT MAY NOT PASS INSPECTION NEXT YEAR AT THIS TIME. I LIVE IN PA. I HAVE HEARD THAT TOYOTA HAS ACKNOWLEDGED THAT THEY HAVE HAD FRAME ISSUES WITH THE TACOMA (SAME CHASIS), THE EARLY TUNDRAS (I OWN A RECALLED 2000 WITH SAME ISSUE), SEQUOIAS (SAME CHASIS AS TUNDRA...... PLEASE TELL ME THAT THE WILL RECALL MY 4RUNNER. I LOVE THE VEHICLE BUT THE RUST ON THE FRAME WILL KILL IT. *TR

NHTSA #: 10633496
mediumSUSPENSION,STRUCTURE
Filed: Apr 2014

HELLO, I HAVE A 2005 TOYOTA 4RUNNER WITH 57,000 AND THE FRAME IS BADLY RUSTED WITH A HOLE IN THE SUBFRAME AND TOYOTA SAYS THERE IS NO PROBLEM WITH THE 4RUNNER FRAMES BUT DOES ADMIT THEY HAVE PROBLEMS WITH THE TACOMA FRAMES AND THE TRUCKS SHARE THE SAME PLATFORMS. WHAT CAN BE DONE FOR AN OWNER OF A TRUCK THAT HAS A FRAME THAT IS FALLING APART BUT NO RUST ON THE BODY? THE FRAMES ARE POORLY MADE AND CAN GIVE OUT. *TR

NHTSA #: 10584647
mediumSUSPENSION,STRUCTURE,WHEELS
Filed: Apr 2014

I OWN A 2005 TOYOTA 4RUNNER WHICH IS RUSTING ON THE CHASSIS AND REAR END HOUSING TOYOTA TELL ME THAT THERE NO RECALL ON THE 4 RUNNER OR TUNDRA BUT SEQUOIA IS RECALLED THERE MUST BE A COMPLAINT FILED SOME WHERE WE CANNOT WAIT FOR SOMEBODY TO DIE AS A RESULT THE REAR END FALLING OUT OR FRONT END BREAK AWAY YOU MUST CHECK INTO THAT JUST CHECK ONLINE FOR ALL THE COMPLAINTS. *TR

NHTSA #: 10576498
mediumSUSPENSION
Filed: Jul 2013

PASSENGER SIDE A ARM BRACKET BROKE. *TR

NHTSA #: 10523467
mediumSUSPENSION,STRUCTURE
Filed: Aug 2010

MY 2005 TOYOTA 4 RUNNER HAS BECOME SO RUSTED ALONG THE FRAME AND UNDERCARRIAGE THAT THE VEHICLE IS UNSAFE TO DRIVE. I HAVE USED THE VEHICLE FOR HIGHWAY AND NORMAL ROAD USE. I BOUGHT THE VEHICLE BRAND NEW AND HAVE NEVER TOWED ANYTHING. MY TUNDRA WAS PURCHASED AT EXACTLY THE SAME TIME AND HAS BEEN DRIVEN UNDER THE SAME CONDITIONS. IT HAS NO RUST PROBLEMS. THERE SEEMS TO BE A PROBLEM WITH THE UNDERCOATING OF SOME OF TOYOTA'S VEHICLES. ANY INFORMATION YOU HAVE WOULD BE GREATLY APPRECIATED. *TR

NHTSA #: 10347537
mediumSUSPENSION
Filed: Apr 2007

TL*- THE CONTACT OWNS A 2005 TOYOTA 4RUNNER. WHILE DRIVING AT 30 MPH THE VEHICLE BEGAN TO WOBBLE FROM LEFT TO RIGHT. THE CONTACT STATED HE WAS UNABLE TO CONTROL THE VEHICLE WHEN DRIVING MORE THAN 30 MPH DUE TO THE WOBBLING OF THE VEHICLE. THE DEALER STATED THAT IT APPEARED THAT THE STABILIZER BAR WAS CUT IN HALF BY A HACKSAW. THE DEALER REPLACED THE STABILIZER BAR, AND THERE HAVE NOT BEEN ANY OTHER OCCURRENCES. THE VEHICLE CURRENT MILEAGE WAS 27,000.*AK

NHTSA #: 10186724
mediumSUSPENSION
Filed: Oct 2006

REAR ELECTRONIC HEIGHT CONTROL GOES TO THE HIGHEST POSITION AND STAY THERE. TAKEN TO THE DEALER X3. THE FACT THAT THERE IS NO FAILSAFE TO PREVENT THE VEHICLE FROM STAYING IN THE HIGH POSITION AND BEING DRIVEN WHEN THE VEHICLE IS UNSTABLE AND A ROLLOVER RISK. *NM

NHTSA #: 10172080
mediumSUSPENSION
Filed: May 2006

STEERING WHEEL PULLS TO THE RIGHT WHEN BRAKES APPLIED ,AT RANDOM TIMES( A FEW TIMES IT HAS DONE SAME TO THE LEFT) THIS DOSE NOT OCCUR ALL THE TIME,BUT NEVER GIVES YOU WARNING(ALMOST HIT ANOTHER CAR LAST WEEK IT PULLED SO HARD) THIS VERY SELDOM HAPPENS TWICE IN A ROW ,I KNOW THIS IS A VERY HARD PROBLEM TO FIND BUT I'M AFRAID THIS WILL CAUSE A ACCIDENT SOONER OR LATER ??? THERE MUST BE SOMEONE WHO HAS HAD THIS PROBLEM OR CAN FIND A ANSWER ????*JB

NHTSA #: 10157132

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