Owners have filed 261 complaints
about the 2002 Toyota 4RUNNER with NHTSA between 2006 and 2024.
The largest single group is the body & structure.
Across this model's run it ranks 18 of 34 worst.
The letter says how bad. This says what kind — whether this year drew
an unusual number of complaints, unusually dangerous
ones, or failures that arrived unusually early.
The dashed ring is 50 — the national norm. Further out is worse.
Complaint volume — 71
Against the median year of the Toyota 4RUNNER. 50 means typical for this
model; 100 means roughly double.
Severity — 55
10.7% of these complaints
involved a crash, fire, injury or death, against a national rate of
9.7%.
Early failure — 5
3% of failures with a mileage on record happened under
36,000 miles, against a national rate of
29%.
NHTSA files every complaint against a named sub-assembly, not just a
system. This is the difference between knowing it was "the engine" and
knowing which part of it — the list to hand a mechanic.
Body
7474.0%
Underbody Shields
88.0%
Lower Ball Joint
77.0%
Frame AND Members
55.0%
Driveline
22.0%
Rear
22.0%
Pressure Monitoring AND Regulating Systems
11.0%
Differential Unit
11.0%
When it fails
Odometer readings owners gave when they filed. About half of all
complaints include one.
Under 1,000 miles
63.0%
25,000 – 49,999 miles
31.5%
50,000 – 74,999 miles
189.0%
75,000 – 99,999 miles
168.0%
100,000 – 149,999 miles
8341.5%
150,000+ miles
7437.0%
NHTSA crash tests
The agency crash-tested this model year itself. These are its own
photographs and star ratings.
These stars come from the pre-2011 crash test programme. NHTSA
rebuilt the programme for the 2011 model year and states that
ratings either side of that change are not comparable — so do
not read these against a 2011-or-newer car's stars.
Frontal crash test
Side barrier crash test
Photographs taken by NHTSA during its own New Car Assessment Program crash
tests of this model year. Public domain.
Configuration
Overall
Front
Side
Rollover
2002 Toyota 4Runner 4-DR.
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—
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When owners complained
A spike years after the car went on sale usually means a part wearing
out on schedule across the whole fleet — the kind of pattern no single
owner can see from inside their own car.
Mar 2006peak 11Jun 2024
NHTSA investigations into the 2002 Toyota 4RUNNER
An investigation is the step before a recall: the agency has seen enough
complaints to look into a pattern itself. An open one means it thinks
something may be wrong and nothing has been fixed yet.
DP18002Opened 17 Aug 2018Closed 18 Mar 2022STRUCTURE:FRAME AND MEMBERS
Frame corrosion
On August 7, 2018, the Office of Defects Investigation (ODI) received a defect petition from Mr. Gary Weinreich alleging premature frame corrosion failure in model year (MY) 2002 - 2006 Toyota 4Runner vehicles. The petitioner based his request upon a corrosion-related front suspension failure he experienced in his MY 2005 Toyota 4Runner, a class action lawsuit settlement involving other Toyota products, and other complaints of underbody corrosion in Toyota 4Runner vehicles that he found in NHTSA?s online complaint database. The petitioner submitted a complaint to NHTSA documenting his experien...
Recalls on the 2002 Toyota 4RUNNER
A complaint is one owner's allegation. A recall is the point at which
the manufacturer or a regulator agreed the defect is real and dangerous
enough to fix for free — however old the car is.
Canada — Transport Canada
Canada runs its own recall programme, and its campaigns do not
always mirror the American ones.
Recall 200515114,341 units in Canada
Suspension
On certain vehicles, a manufacturing issue with the front lower ball joint could result in premature wear. If the vehicle is operated for an extended period of time in this condition, the ball joint may eventually experience excessive wear and looseness, resulting in increased steering effort, reduced vehicle self-centering and noise in the front suspension. In extreme cases, when the driver continues to operate the vehicle in this condition, the lower ball joint may separate from the knuckle causing a loss of vehicle steering control. Correction: Dealers will inspect and, if necessary, replace the front lower ball joints.
Reports where the owner recorded a crash, a fire, an injury or a death.
Winnemucca, NVCrash1 injured
AIR BAGS
TL* THE CONTACT OWNS A 2002 TOYOTA 4RUNNER. WHILE DRIVING 35 MPH, THE CONTACT REAR ENDED ANOTHER VEHICLE. THE AIR BAGS FAILED TO DEPLOY. THERE WERE NO WARNING INDICATORS ILLUMINATED. THE CONTACT SUSTAINED UPPER AND LOWER BACK INJURIES THAT REQUIRED MEDICAL ATTENTION. A POLICE REPORT WAS FILED. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC FOR BODY REPAIR, BUT THE AIR BAG FAILURE WAS NOT DIAGNOSED. THE LOCAL TOYOTA DEALER WAS NOT CONTACTED FOR DIAGNOSTIC TESTING. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS UNKNOWN.
NHTSA complaint #11110848 — an unverified report by a vehicle owner.
at 111,000 milesAlameda, CACrash1 injured
AIR BAGS
AIRBAG DID NOT DEPLOY IN TOTAL LOSS ACCIDENT. SENSOR WAS DAMAGED, YET DID NOT DEPLOY THE AIRBAG TOYOTA COMPANY WOULD NOT GIVE THE MAKE AND NAME OF THE AIRBAG
NHTSA complaint #11055734 — an unverified report by a vehicle owner.
at 73,000 milesSalt Lake City, UTCrash2 injured
SEAT BELTS
I WAS AT A FULL STOP, BEHIND A LINE OF CARS, AT A RED LIGHT, ON A CITY STREET. A JEEP LIBERTY SUV REAR-ENDED ME AT APPROXIMATELY 30 MPH, PUSHING ME INTO THE CAR IN FRONT OF ME, AND TOTALING MY VEHICLE. MY SHOULDER BELT DID NOT LOCK IN PLACE, CAUSING ME TO HIT, AND CRACK, THE WINDSHIELD, WITH THE LEFT FRONTAL ASPECT OF MY SKULL, RESULTING IN A CONCUSSION. THE DRIVER OF THE VEHICLE THAT RAN INTO ME, WAS TAKEN BY AMBULANCE TO THE HOSPITAL. WHILE MY CAR WAS AT THE COLLISION REPAIR CENTER, BEFORE IT WAS TAKEN TO SALVAGE, I WENT TO GATHER MY BELONGINGS THAT WERE INSIDE MY 4RUNNER. AT THE RECOMMENDATION OF MY LOCAL TOYOTA DEALER SERVICE MANAGER, I REPEATEDLY TESTED BOTH THE DRIVER, AND FRONT PASSENGER SHOULDER BELTS, BY ABRUPTLY AND RAPIDLY PULLING ON THEM. THE DRIVER SIDE BELT ONLY LOCKED IN PLACE ONCE, DURING APPROXIMATELY 10 TRIALS. THE PASSENGER SHOULDER BELT LOCKED IN PLACE EVERY TIME.
NHTSA complaint #11043443 — an unverified report by a vehicle owner.
at 112,000 milesA, CACrash1 injured
AIR BAGS
AIRBAG DID NOT DEPLOY AND TOYOTA WOULD NOT GIVE THE NAME AND TYPE AND BRAND AND THE MAKER NAMES OF THE AIRBAG. TOYOTA IS ASKING ME TO GO TO COURT TO HAVE THE COURT ORDER THEM TO RELEASE THE AIRBAG SPECIFICATIONS AND THE TYPE AND BRAND AND THE MAKER. CAN YOU MAKE TOYOTA GIVE ME THIS INFORMATION?
NHTSA complaint #11000680 — an unverified report by a vehicle owner.
at 120,000 milesReads Landing, MNCrash4 injured
SUSPENSION
TAKATA RECALL. I HAVE A RUSTY FRAME THAT NEEDS TO BE ADDRESSED FOR SAFETY REASONS I WAS DRIVING ON THE HIGHWAY AT 55 MPH FRAME CRACKED AND I ALMOST DIED BECAUSE OF IT TOYOTAS HAVE POOR FRAME THAT SHOULD BE RECALLED
NHTSA complaint #10978709 — an unverified report by a vehicle owner.
at 120,000 milesReads Landing, MNCrash4 injured
STRUCTURE:BODY
TAKATA RECALL. I HAVE A RUSTY FRAME THAT NEEDS TO BE ADDRESSED FOR SAFETY REASONS I WAS DRIVING ON THE HIGHWAY AT 55 MPH FRAME CRACKED AND I ALMOST DIED BECAUSE OF IT TOYOTAS HAVE POOR FRAME THAT SHOULD BE RECALLED
NHTSA complaint #10978709 — an unverified report by a vehicle owner.
The most recent complaints
In the owners' own words, exactly as filed with NHTSA.
Miami, FL
TIRES
THIS IS FOR TIRE SIZE P265 75 16. To start, I've seen multiple other complaints describing the same scenario and type of incident. Driving along the highway at appropriate speeds, I hear a whoosh/deep pitch rumble, then my vehicle began to vibrate violently. I was luckily able to pull over but had to swerve to regain control of my vehicle once the rumbling and vibration got too severe since it happened so quickly. Witnessed my driver side rear tire completely shredded, no damage along tread material, only on sidewall with multiple tears/punctures. This was a center lane on the highway with no debris. I'm now noticing other similar "tear/wear" signs on my other 3 tires on the vehicle. All specifically on the sidewall along the aggressive tread that the AT3W tires were known to have for extra grip. It just seems to be separating over time.
NHTSA complaint #11594739 — an unverified report by a vehicle owner.
Marion, OH
UNKNOWN OR OTHER
Frame rot
NHTSA complaint #11531971 — an unverified report by a vehicle owner.
Marion, OH
STRUCTURE:BODY
Frame rot
NHTSA complaint #11531971 — an unverified report by a vehicle owner.
at 160,000 milesColchester, CT
STRUCTURE:FRAME AND MEMBERS
The contact owns a 2002 Toyota 4Runner. The contact stated that while inspecting underneath the vehicle, he noticed that there was a hole in the subframe and that the subframe and sway bar were corroded. The vehicle was not diagnosed or repaired by an independent mechanic or dealer. The manufacturer was not made aware of the failure. The failure mileage was approximately 160,000.
NHTSA complaint #11522804 — an unverified report by a vehicle owner.
at 160,000 milesColchester, CT
STRUCTURE:FRAME AND MEMBERS:UNDERBODY SHIELDS
The contact owns a 2002 Toyota 4Runner. The contact stated that while inspecting underneath the vehicle, he noticed that there was a hole in the subframe and that the subframe and sway bar were corroded. The vehicle was not diagnosed or repaired by an independent mechanic or dealer. The manufacturer was not made aware of the failure. The failure mileage was approximately 160,000.
NHTSA complaint #11522804 — an unverified report by a vehicle owner.
at 150,000 milesWashington, DC
LATCHES/LOCKS/LINKAGES:DOORS:LATCH
The contact owns a 2002 Toyota 4Runner. The contact stated while pulling the door handle to unlock the doors, the auto unlock function failed to unlock the doors. The contact had to press the unlock button to unlock the vehicle. The vehicle was taken to the dealer to be diagnosed and the dealer stated that a failure was not found. The vehicle was not repaired. The manufacturer was not contacted. The failure mileage was 150,000.
NHTSA complaint #11511032 — an unverified report by a vehicle owner.
Mount Holly, NJ
STRUCTURE:BODY
Frame is excessively rusted. The recall that already exists for this issue only covers certain frames from Japan made with this steel. However, the same frames were imported to America and a large percentage of 4Runners were made with the same steel and didn’t receive a recall. Mine is one of them.
NHTSA complaint #11482461 — an unverified report by a vehicle owner.
Garfield, NJ
UNKNOWN OR OTHER
frame rust saftey hazardous? midas mechanic pointed out to me while work being done on exhaust march 2022
NHTSA complaint #11466536 — an unverified report by a vehicle owner.
at 115,000 milesMadisonville, TX
SUSPENSION
The contact owns a 2002 Toyota 4Runner. The contact stated that while driving 60 MPH through a slight right curve, the vehicle independently shifted from side to side without warning nearly causing the vehicle to flip. The contact had an independent mechanic inspect the vehicle and the mechanic discovered severe corrosion throughout the entire subframe of the vehicle. The mechanic informed him that the entire subframe needed to be replaced to ensure safe driving. Neither the dealer nor the manufacturer had been notified of the failure. The vehicle had yet to be repaired. The failure mileage was approximately 115,000.
NHTSA complaint #11461138 — an unverified report by a vehicle owner.
at 115,000 milesMadisonville, TX
STRUCTURE:FRAME AND MEMBERS:UNDERBODY SHIELDS
The contact owns a 2002 Toyota 4Runner. The contact stated that while driving 60 MPH through a slight right curve, the vehicle independently shifted from side to side without warning nearly causing the vehicle to flip. The contact had an independent mechanic inspect the vehicle and the mechanic discovered severe corrosion throughout the entire subframe of the vehicle. The mechanic informed him that the entire subframe needed to be replaced to ensure safe driving. Neither the dealer nor the manufacturer had been notified of the failure. The vehicle had yet to be repaired. The failure mileage was approximately 115,000.
NHTSA complaint #11461138 — an unverified report by a vehicle owner.
Leonardtown, MD
UNKNOWN OR OTHER
Frame rusted through from the inside out. There isnt even any surface rust where the hole started. Its just a hole in the middle of clean metal. The rest of the frame rail is solid. Rear suspension arm mount is also rusted out and starting to come off. The entire structural integrity of the frame is in question, even though externally, theres only slight surface rust. The frame should not be rusting this way.
NHTSA complaint #11453546 — an unverified report by a vehicle owner.
Simsbury, CT
STRUCTURE:BODY
Premature rusted frame throughout, vehicle is garaged and well maintained 117,000 miles on my 2002 Toyota 4Runner. Auto body specialist estimates $3k-$4k to restore, at least.
NHTSA complaint #11451258 — an unverified report by a vehicle owner.
Marshfield, MA
SUSPENSION
Frame and rear passenger control arm bracket, rotted out .only there, 2 nd time this has happened, same spot but on my previous 2001 4runner
NHTSA complaint #11443916 — an unverified report by a vehicle owner.
Marshfield, MA
STRUCTURE:BODY
Frame and rear passenger control arm bracket, rotted out .only there, 2 nd time this has happened, same spot but on my previous 2001 4runner
NHTSA complaint #11443916 — an unverified report by a vehicle owner.
Silver Spring, MD
UNKNOWN OR OTHER
Had vehicle inspected on Oct. 1 ,2021 for road trip to North Carolina from Washington, DC. Was informed that my vehicle is unsafe by the automotive shop (name withheld) due to [rusting] frame front suspension components' threads rusted off on bolts that hold suspension, control arms, and shocks on both front and rear areas + body of vehicle located where shocks bolt to the body. I also had two other shops (names withheld) assess the state of the frame and suspension + and was told that the vehicle has maybe 1 year or so until the frame falls apart. Given I am the original owner, have gargage-kept my vehicle, have very low-mileage - 74,000 miles, and have maintained the vehicle immaculately and am aware of rusting problems with other Toyota [truck] frames, etc. this seems to be a defect in the manufacturing process. I know there have been recalls on Toyota's other trucks due to Toyota's failure to add [enough?] rust inhibitor/preventative to the molten steel when forming the frame for many models of their trucks.
NHTSA complaint #11438485 — an unverified report by a vehicle owner.
Silver Spring, MD
SUSPENSION
Had vehicle inspected on Oct. 1 ,2021 for road trip to North Carolina from Washington, DC. Was informed that my vehicle is unsafe by the automotive shop (name withheld) due to [rusting] frame front suspension components' threads rusted off on bolts that hold suspension, control arms, and shocks on both front and rear areas + body of vehicle located where shocks bolt to the body. I also had two other shops (names withheld) assess the state of the frame and suspension + and was told that the vehicle has maybe 1 year or so until the frame falls apart. Given I am the original owner, have gargage-kept my vehicle, have very low-mileage - 74,000 miles, and have maintained the vehicle immaculately and am aware of rusting problems with other Toyota [truck] frames, etc. this seems to be a defect in the manufacturing process. I know there have been recalls on Toyota's other trucks due to Toyota's failure to add [enough?] rust inhibitor/preventative to the molten steel when forming the frame for many models of their trucks.
NHTSA complaint #11438485 — an unverified report by a vehicle owner.
Silver Spring, MD
STRUCTURE:BODY
Had vehicle inspected on Oct. 1 ,2021 for road trip to North Carolina from Washington, DC. Was informed that my vehicle is unsafe by the automotive shop (name withheld) due to [rusting] frame front suspension components' threads rusted off on bolts that hold suspension, control arms, and shocks on both front and rear areas + body of vehicle located where shocks bolt to the body. I also had two other shops (names withheld) assess the state of the frame and suspension + and was told that the vehicle has maybe 1 year or so until the frame falls apart. Given I am the original owner, have gargage-kept my vehicle, have very low-mileage - 74,000 miles, and have maintained the vehicle immaculately and am aware of rusting problems with other Toyota [truck] frames, etc. this seems to be a defect in the manufacturing process. I know there have been recalls on Toyota's other trucks due to Toyota's failure to add [enough?] rust inhibitor/preventative to the molten steel when forming the frame for many models of their trucks.
NHTSA complaint #11438485 — an unverified report by a vehicle owner.
at 136,000 milesAshland, MA
STRUCTURE
The contact owns a 2002 Toyota 4Runner. The contact stated that while receiving routine maintenance repair on the vehicle, the independent mechanic informed the contact that the subframe was rusted. The dealer was not contacted. The vehicle was not repaired. The manufacturer was not notified of the failure. The approximate failure mileage was 136,000.
NHTSA complaint #11431008 — an unverified report by a vehicle owner.
Cedar Falls, IA
UNKNOWN OR OTHER
After having my 4 runner in for routine maintenance, my mechanic informed me that my frame was in bad condition and rusting through. Doubtful it has a year left and he advised me to junk it as fast as I can. 180;000 miles - so much for Toyota’s lasting a long time.
NHTSA complaint #11424088 — an unverified report by a vehicle owner.
Cedar Falls, IA
SUSPENSION
After having my 4 runner in for routine maintenance, my mechanic informed me that my frame was in bad condition and rusting through. Doubtful it has a year left and he advised me to junk it as fast as I can. 180;000 miles - so much for Toyota’s lasting a long time.
NHTSA complaint #11424088 — an unverified report by a vehicle owner.
Cedar Falls, IA
STRUCTURE:BODY
After having my 4 runner in for routine maintenance, my mechanic informed me that my frame was in bad condition and rusting through. Doubtful it has a year left and he advised me to junk it as fast as I can. 180;000 miles - so much for Toyota’s lasting a long time.
NHTSA complaint #11424088 — an unverified report by a vehicle owner.
at 100,000 milesLogan, OH
STRUCTURE:BODY
FRAME IS SHOWING EXCESSIVE RUST ALL OVER, A KNOWN PROBLEMS WITH 4RUNNERS AND TOYOTA TRUCKS. AUTO REPAIR SHOP SAYS VEHICLE PROBABLY HAS ONLY 1 YEAR OF LIFE LEFT BEFORE UNSAFE AND UNDRIVABLE. CAR HAS ONLY 100000 MILES ON IT, 1998 4RUNNER WE HAD MADE IT TO 250000 MILES- UNACCEPTABLE.
NHTSA complaint #11413734 — an unverified report by a vehicle owner.
at 278,000 milesGreenville, OH
STRUCTURE:BODY
I RECENTLY HAD MY VEHICLE IN FOR SERVICE AND TO GET NEW TIRES. WHILE ON THE LIFT, THE MECHANIC POINTED OUT TO ME THAT THE FRAME ON THE PASSENGER'S SIDE IS BEGINNING TO RUST THROUGH. THIS IS AN OBVIOUS POTENTIAL SAFETY ISSUE AND AS I HAVE RESEARCHED POSSIBLE REPAIRS, IT APPEARS THAT THIS IS A VERY COMMON PROBLEM FOR THIS YEAR AND MODEL. THIS SHOULD BE RECALLED.
NHTSA complaint #11405965 — an unverified report by a vehicle owner.
at 116,000 milesSchoharie, NY
UNKNOWN OR OTHER
THE FRAME HAS RUSTED AT THE PASSENGER SIDE REAR CONTROL ARM MOUNT TO THE POINT OF NOT PASSING INSPECTION.
NHTSA complaint #11405818 — an unverified report by a vehicle owner.
at 202,000 milesNatrona Heights, PA
UNKNOWN OR OTHER
THE FRAME IS RUSTED OUT AND IS MAKING THE VEHICLE UNSAFE TO BE ON THE ROAD. THIS IS A KNOWN PROBLEM WITH THIS FRAME, IT'S ALREADY BEEN RECALLED ON THE TOYOTA TACOMA AND IT'S THE SAME IDENTICAL FRAME. IT SHOULD HAVE BEEN RECALLED YEARS AGO. JUST MAKING A NORMAL TURN ON A BEND IN THE ROAD MAKES IT DIFFICULT TO KEEP THE VEHICLE UNDER CONTROL.
NHTSA complaint #11403610 — an unverified report by a vehicle owner.
