2003 Toyota 4RUNNER suspension problems

SUSPENSION

I purchased this 2003 Toyota 4Runner in 2018 under what I assumed was prime condition, for a vehicle that spent the majority of its life in Nebraska/Kansas before I moved to Texas in 2021. At 87,400 miles at the time of purchase, the vehicle had no visible damage to the exterior besides a few paint chips, some minor hail damage and scratches, and some easily fixed surface rust in the paint on the tailgate. The previous owner had driven it leisurely and had kept the miles low after 15 years. The car has had some mechanical issues, but nothing out of the ordinary outside of some regular maintenance over the first few years. Being close to 100,000 miles, the timing belt and pump was replaced around 98,000 miles. Other issues have been fixed periodically, please reference the attached files. After joining a Toyota 4Runner 4th Generation Facebook group and seeing a post about another's issues with rust damage in October 2020, I decided to take a look at my own frame. I then inspected my own vehicle, and found significant frame rot damage. It is extensive, with significant rust to the frame, with large holes and soft patches that question the integrity of the frame and the safety of the vehicle on the road. Every time I hit a small bump or pothole, I fear the frame will crack and I will lose control as others have. I have not sought out professional repairs due to the extensive cost, and am awaiting the outcome of a current class action lawsuit by the Bell Legal Group. The 4th Generation Toyota 4Runner (2003-2009) is built on the exact same frame as the Toyota Tacoma of that era, yet while the Tacoma was recalled for frame rot, the 4Runner was not included, which I believe to be a gross oversight in previous legal proceedings. The 2003-2009 Toyota 4Runner is a reliable vehicle, but poses significant frame rot issues much earlier than should be expected.

NHTSA complaint #11500005 — an unverified report by a vehicle owner.

SUSPENSION

There is severe rust on the frame, the rear is listing by 3/4 of an inch due to suspension rust, parts of the frame are perforated and lots of rust can fall out of drain holes when tapped. I am unable to steer the truck due to the intermediate steering column rust. The Tacoma was recalled for the same reason, I am assuming the 4runner has not been recalled because it was manufactured in greater numbers, and therefore more costly to repair, the danger of the severe rust is the same in both vehicles.

NHTSA complaint #11481057 — an unverified report by a vehicle owner.

SUSPENSION

Stabilizer bar connected to the frame rusted off,back passenger side! Causing the vehicle to sway uncontrollably, due to the low rate of speed, I was able to regain control of my vehicle and not drive off the bridge I was driving over at the time or crash into another vehicle. The engine runs great, everything works, the vehicle still looks good but the frame is rusting out from underneath it! Toyota Needs To Make It Right!

NHTSA complaint #11474433 — an unverified report by a vehicle owner.

SUSPENSION

Stabilizer bar connecting the axle to the frame rusted off. I was driving only 25-30mph at the time, luckily. The vehicle swayed violently almost causing an accident and nearly forcing me off the bridge I happened to driving over. Very fortunate no one was hurt and nothing was damaged from the incident. You can imagine the tragedy if that had happened on the highway driving 75mph! Major accident, innocent lives damaged or lost. This is a very dangerous vehicle not only to the driver and passengers but also to anybody that happened to be innocently in the path of an out of control Toyota 4runner. Toyota Please fix this, for your safety and everyone else on the highway. People should be warned!!

NHTSA complaint #11474448 — an unverified report by a vehicle owner.

SUSPENSION

The rust and corrosion underneath the vehicle continually gets worse year after year. The main components of vehicle relating to the engine, powertrain and suspension underneath vehicle are corroded; holes exist in the frame of the truck through out. The frame of truck is rotted due to not being sealed properly during the manufacturing process. Due to the rust and corrosion on the frame of truck, it is impossible to get work done on exhaust and muffler areas. I will send pictures for your reference. This makes driving a safety concern for myself and my son. At this time, I am unable to purchase a new car and do not have money to replace/fix the frame of truck. Inevitably, this problem will get worse and may cause a safety concern for myself and others on the road. I called Toyota on 4/12/22 and was told that there is not a recall for this issue and that any repairs would have to be paid by me. I then proceeded to call the number given to me by the representative to call 800-331-4331 for the Toyota Corporate office. I spoke to Blake who gave me the same answer, there was not a recall on this vehicle for rust/corrosion on the frame of vehicle. At this time, Toyota charges $150 just to check car and unfortunately, I don't have those funds to pay such a fee. I asked Blake if there was a way, Toyota can check without charging a fee and his answer was no. Currently, there is not any warning lights on, but with increased time and pressure of exhaust pipe and muffler will create more problems. I cannot have the exhaust system fixed until the frame of truck is replaced. My car was checked by an independent shop.

NHTSA complaint #11460830 — an unverified report by a vehicle owner.

SUSPENSION

I own a 2003 Toyota 4Runner with very low mileage for its age. It has been garage kept for most of its life. I was experiencing difficulty steering, and when I took the car to a mechanic, it was determined that the frame was prematurely rusted and rotted to a dangerous level putting my life at risk while driving it.

NHTSA complaint #11434215 — an unverified report by a vehicle owner.

SUSPENSION

I have not actually had an incident yet, but have been advised by the Toyota service team that I should no longer tow trailers and should consider not driving it at all due to frame rust/perforation in front of the rear control arms. This has been a well cared for vehicle that is in otherwise great shape (It has had every repair the dealership has ever recommended) the vehicle was bought per the dealerships claim that it could be driven "forever" as long as the dealership takes care of it. And now I'm faced with a massive expense to repair or replace the vehicle.

NHTSA complaint #11433476 — an unverified report by a vehicle owner.

SUSPENSION

The main rust issues are claims arising out of a pending class action lawsuit pleadings’ that the Toyota Manufacturer perform at no cost inspections, in addition to dire emergency needed replacement of including my 2003 Toyota 4Runner frame because of premature rusting of the undercarriage-my vehicle’s frame due to improper treatment against rust corrosion during manufacturing-inadequate rust protection, which has lead to severe excessive rust corrosion significant enough to affect structural integrity, compromising the vehicle’s safety, stability & crash-worthiness, & poses a dangerous risk.

NHTSA complaint #11433249 — an unverified report by a vehicle owner.

SUSPENSION

The contact owns a 2003 Toyota 4Runner. The contact stated that while driving at limited speeds of 45 mph, the vehicle would wobble and swerve and was very unstable. The vehicle was taken to a Certified Auto Mechanic Shop and an independent mechanic who diagnosed that the failure was caused by severe rusting, perforation and corrosion of the rear subframe and suspension system. The vehicle was also driven to Muffler Shops in Bladensburg, MD on 8-20-2021, and on 10 -22-2021 to Hyattsville Toyota's Certified Toyota Collision Center for Repair Estimates of $4,000.00 and $7,268.00. The vehicle frame manufactured by Dana Holding Corporation which really requires fixing or replacing was not yet repaired. The Toyota manufacturer and local dealer Global Auto Outlet were notified of the failure. The approximate failure mileage was 1 85,000. The used vehicle was purchased from Global Auto Outlet in Temple Hills, MD for $9,552.24 on 8 -1-2019 with 175,000 miles on the odometer. The windshield had a crack in it, the air conditioning & emergency brake didn't work. The Complainant hadn't noticed the perforated excessive rust corrosion on the undercarriage of the vehicle until numerous months afterwards. Moreover, at the time of the purchase the Owner also didn't notice that the spare tire carrier was rusted, as well as undiscovered that the wrong size 265/65/17 spare tire it was held in was perforated and flat. After the purchase of the vehicle shortly later, the exhaust tailpipe rusted broke first and the muffler had to be replaced which costed $258.79. The Owner was nervously forced to operate a more than unsafe motor vehicle for up to 6 months.

NHTSA complaint #11432719 — an unverified report by a vehicle owner.

SUSPENSION

At the end of June 2021, while driving I experienced a loud clunk and grinding noise, with reduced control of steering and brakes on my 4Runner. I took the 4Runner to a Goodyear Automotive Service Center on Woodward Avenue in Royal Oak, Michigan, who told me that the vehicle was not driveable due to severe rust damage of the frame that resulted in a broken sway bar. I thought I should take it to the closest Toyota dealership in Troy, Michigan for advice and they responded that the vehicle was beyond repair and that a new frame would cost around $20,000. I could not leave my car there, and risked driving it home, where it has been parked ever since.

NHTSA complaint #11431046 — an unverified report by a vehicle owner.

SUSPENSION

No Accident - Items need to be investigated for Safety Defects on Toyota's. 1> Front Brake Calipers (constant freezing of the front brake calipers). 2> Dash Cover (excessive cracking on the dash covers especially areas that contain airbags). 3> Fuel Pump Connection (on top of fuel tank, connection to fuel pump appears to create a short, which in turn causes vehicle to stall also could cause a fire). 4> Excessive Frame Rust (frame has excessive rust outside and inside which is causing frame to fail. this is a manufacturing issue). These are ongoing issues with Toyota that have been reported and nothing is being done about it. Multiple 4runners are having big time Excessive Frame Rust, which are causing the frame coming apart during highway driving. These photo's show the rust on the outside and inside, all metal is having rust issues. Paint has been applied to cover said rust but it still reappears with-in a few months. Best way to contact me is via e-mail.

NHTSA complaint #11424180 — an unverified report by a vehicle owner.

SUSPENSION

I heard a loud noise (scraping-dragging) from the bottom of the engine area while driving on the highway This was a very dangerous and scary incident Pulled over and My fiancé checked under the engine A very large metal piece was dragging the road I did not hit a bump or anything. A body shop mechanic informed me that the chasis of the 4 runner was in extremely bad condition The 4Runner will not pass inspection because of this condition I respectfully request help in this matter

NHTSA complaint #11421560 — an unverified report by a vehicle owner.

SUSPENSION

Frame is rotted out and brake lines attached to the frame as well as every suspension component. Car failed inspection deemed unsafe to drive. This problem has been addressed for Tacoma, tundra and sequoia but not 4runner. These frames have the same issue as those and needs to be repaired by Toyota due to lack of rust and corrosion protection. There’s no reason 4runner should be overlooked for the same issue as the other full frame trucks.

NHTSA complaint #11421097 — an unverified report by a vehicle owner.

SUSPENSION

FRAME IS COMPLETELY ROTTED OUT RUSTED, GAS TANK STRAPS ARE ROTTED/RUSTED. REAR SWAY BARS ARE ROTTED OFF THE FRAME. THIS VEHICLE HAS THE SAME FRAME ISSUE AS THE TACOMA AND SEQUOIA FRAMES THAT ARE ON RECALL.

NHTSA complaint #11416446 — an unverified report by a vehicle owner.

SUSPENSION

ADDING MY NAME TO THE LIST OF PEOPLE WHO HAVE EXPERIENCED EXCESSIVE AND PREMATURE FRAME RUST ON THEIR 4RUNNER, POTENTIALLY CAUSING UNSAFE CONDITIONS WHICH COULD LEAD TO A COLLISION. TOYOTA ADDRESSED THIS PROBLEM FOR THE TACOMA, SEQUOIA, AND TUNDRA OF THE SAME YEARS, AND THEY SHOULD DO THE SAME FOR THE 4RUNNER.

NHTSA complaint #11415229 — an unverified report by a vehicle owner.

SUSPENSION

I HAVE BEEN IN CONTACT WITH TOYOTA SEVERAL TIMES OVER THE PAST 4 YEARS ABOUT RUST ISSUES WITH THIS FRAME, BUT THE REFUSE TO FIX IT. THEY RECALLED THE TACOMA, TUNDRA AND SEQUOIA OF THE SAME YEAR FOR THIS REASON. THE FRAME RUSTS AND FALLS APART. WHILE DRIVING UP MY ROAD I FELT THE REAR OF THE CAR SHIFT TO THE SIDE, I TURNED AROUND AND WENT STRAIGHT HOME TO FIND THE FRAME AT THE REAR PASSENGER TIRE BROKEN. I HAVE ATTACHED A PICTURE OF THE BROKEN AREA, BUT CAN SEND MORE PICTURES OF THE ENTIRE FRAME IF NEEDED.

NHTSA complaint #11413582 — an unverified report by a vehicle owner.

SUSPENSION

THE FRAME IS RUSTED BEYOND REPAIR AND THE VEHICLE HAS SPENT THE MAJORITY OF ITS LIFE IN A N UNDERGROUND GARAGE PROTECTED FROM THE ELEMENTS, AS WELL AS IN FLORIDA. IT HAS VERY LOW MILEAGE, AND NO OTHER SERIOUS PROBLEMS.

NHTSA complaint #11407015 — an unverified report by a vehicle owner.

SUSPENSION

FRAME IS RUSTED OUT, EXCESSIVE RUST THROUGHOUT THE ENTIRE FRAME AND SUSPENSION COMPONENTS. SWAY BAR MOUNTS FOR REAR AXLE HAVE RUSTED OUT VEHICLE IS UNSAFE TO DRIVE

NHTSA complaint #11406493 — an unverified report by a vehicle owner.

SUSPENSION

EXTREME RUST AND CORROSION IN FRAME, SUSPENSION COMPONENTS. THIS WILL LEAD TO CATASTROPHIC FAILURE AT SOME POINT IF HOLES AND FRAME DETERIORATION IS NOT ADDRESSED QUICKLY.

NHTSA complaint #11406565 — an unverified report by a vehicle owner.

SUSPENSION

EXTREME CORROSION OF FRAME AND BRACKETS

NHTSA complaint #11404362 — an unverified report by a vehicle owner.

SUSPENSION

LOUD NOISE WHILE DRIVING. UPON INSPECTION, EXCESSIVE RUST AND CORROSION TO FRAME OF VEHICLE FOUND. HOLES IN FRAME LARGER THAN 2 INCHES.

NHTSA complaint #11403492 — an unverified report by a vehicle owner.

SUSPENSION

THE REAR TIRE ASSEMBLY RIPPED LOOSE FROM ITS MOUNTS UNDER NORMAL DRIVING CONDITIONS..A LOUD CLUNK NOISE....THEN .BRAKES WERE LOST AND THE ELECTRICAL SYSTEM SHOWED WARNING LIGHTS ON DASH BOARD...CAR IS NOT DRIVABLE...MASSIVE RUST AT FAILURE POINTS

NHTSA complaint #11394884 — an unverified report by a vehicle owner.

SUSPENSION

REAR DRIVER SIDE CONTROL ARM BROKE OFF AT THE FRAME AFTER STRIKING POTHOLE AT HIGHWAY SPEED. AFTER THE FAILURE THE VEHICLE WAS VERY HARD TO CONTROL AND ALMOST LED TO A ROLLOVER. THE VEHICLE WAS UNABLE TO BE DRIVEN AND HAD TO BE TOWED. TOYOTA RECALLED TUNDRA'S, TACOMA'S, AND SEQUOIA'S FOR FRAME REPLACEMENT SO IT IS A KNOWN PROBLEM. WILL TOYOTA BE HELD LIABLE FOR ACCIDENTS RESULTING FROM PREMATURE FRAME FAILURE? BY RECALLING THE OTHER MODELS THEY OBVIOUSLY ACKNOWLEDGED IT WAS A PROBLEM AND 4RUNNERS SHARE THE SAME PLATFORM AS THE TACOMA SO WHY WERE THEY NOT INCLUDED?

NHTSA complaint #11391057 — an unverified report by a vehicle owner.

SUSPENSION

MY 2003 TOYOTA 4 RUNNER SR5 WAS SWAYING BACK AND FORTH AT SPEEDS UP TO 35 MPH SOMETHING IS WRONG THINKING MAYBE THE SWAY BARS SO TOOK IT TO A MECHANIC AND AFTER HE DROVE IT AND PUT IT UP ON A LIFT HE WAS FRIGHTENED ON HOW MUCH RUST AND SEPARATION ON THE FRAME ESPECIALLY THE REAR PASSENGER SIDE RIGHT NEXT TO THE MUFFLER COMPLETE SEPARATION AND THEN YOU WALK TO THE MIDDLE ANY DAY NOW THAT WOULD HAVE SEPARATED .I WAS TOLD TO TO HAVE A TOW TRUCK TAKE IT BACK TO MY HOUSE WHICH IS ABOUT TWO-THREE MILES AWAY WHICH I DID BUT NOW IT SITS IN MY GARAGE - AND WITH ONLY 139,000 MILE ON IT NOT ABLE TO DRIVE OR SELL UNLESS ITS FOR JUNK.

NHTSA complaint #11389661 — an unverified report by a vehicle owner.

SUSPENSION

VEHICLE FRAME IS SEVERELY RUSTED AND ROTTED TO THE POINT WHERE THERE ARE HOLES IN THE FRAME ITSELF MAKING IT EXTREMELY UNSAFE TO DRIVE. OTHER TOYOTA TRUCKS AROUND THE SAME YEAR HAVE BEEN RECALLED WITH SIMILAR FRAME ISSUES, DOES NOT MAKE ANY SENSE WHY TOYOTA HAS NOT RECALLED THE 2003 4RUNNER FRAMES YET. VEHICLE IS OVER 205,000 MILES AND WOULD PROBABLY RUN ANOTHER 200K IF NOT FOR THE FRAME WHICH MAKES THIS CAR ALMOST UNDRIVE-ABLE. FRAME TO BE REPLACED ASAP.

NHTSA complaint #11364763 — an unverified report by a vehicle owner.

SUSPENSION

FRAME IS ALMOST COMPLETELY RUSTED OUT EVEN THOUGHT THE REST OF THE CAR IS IN GOOD SHAPE. I AM AFRAID TO LET MY SON EVEN DRIVE THE CAR. I READ ABOUT THE GIRL THAT DIED FROM THE AXLE COMING LOOSE AND PART OF THE FRAME THAT HOLDS THE AXLE IS IN HORRIBLE SHAPE. TOYOTA SHOULD BE REQUIRED TO ADD THESE VEHICLES TO THE FRAME RECALL...

NHTSA complaint #11364550 — an unverified report by a vehicle owner.

SUSPENSION

THE RUST ON THE FRAME OF THIS VEHICLE IS UNLIKE ANYTHING I'VE SEEN IN COMPARISON TO IT'S AGE. I WORK ON VEHICLES FREQUENTLY AND HAVE NOT SEEN ANYTHING LIKE THIS IN A MODERN AGE VEHICLE, AND VEHICLES THAT ARE OVER 40 YEARS OLD THAT I OWN OR WORK ON DON'T HAVE RUST THAT IS REMOTELY THIS BAD. UPON FURTHER INVESTIGATION, I FOUND THE ENTIRE WELD LINE OF THE FRAME RAILS TO BE CORRODED THROUGH IN AN APPROXIMATELY 28" SECTION. WITH FURTHER INVESTIGATION, THE ENTIRE BOTTOM SECTION OF THAT RAIL WAS RUSTED OUT TO BE EXTREMELY THIN AND SEPARATED AT THE SEAM, ENTIRELY COMPROMISING THE INTEGRITY OF THE FRAME RAIL. 2 OF THE BODY MOUNTS ARE ALSO RUSTED OUT AS WELL AS SOME OF THE SUSPENSION MOUNT COMPONENTS. THE VEHICLE IS AT RISK FOR HAVING THE SPRING AND STRUT ASSEMBLY OR THE CONTROL ARM ASSEMBLY DETACHING FROM THE FRAME UNDER NORMAL OPERATION CONDITIONS. THIS IS AN INCREDIBLE SAFETY RISK AS IT COULD RESULT IN THE VEHICLE LOSING ALL STEERING CONTROL. LUCKILY IT WAS FOUND BEFORE AN ACCIDENT OCCURRED.

NHTSA complaint #11364283 — an unverified report by a vehicle owner.

SUSPENSION

TL* THE CONTACT OWNS A 2003 TOYOTA 4RUNNER. THE CONTACT STATED THAT THE SUBFRAME WAS CORRODED CAUSING BOTH REAR CONTROL ARMS TO DETACH WHILE DRIVING. THE CONTACT INSPECTED UNDER THE VEHICLE AND NOTICED THERE WERE SEVERAL SPOTS COVERED WITH A BLACK TAPE AND PAINTED OVER TO CONCEAL THE RUST AND HOLES. THE CONTACT STATED THAT THE REAR TIRE MOVE FORWARD AND BACKWARD CAUSING THE TIRES TO DAMAGE THE BUMPER AND THE PLASTIC TRIM PANEL. THE VEHICLE WAS TOWED TO THE CONTACT'S RESIDENCE. THE CONTACT CALLED AAA AND INFORMED THEM OF THE FAILURE AND WAS INFORMED TO CONTACT NHTSA. NEITHER THE DEALER NOR THE MANUFACTURER WERE MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS APPROXIMATELY 200,000.

NHTSA complaint #11355585 — an unverified report by a vehicle owner.

SUSPENSION

THE VEHICLE FRAME HAS MULTIPLE PERFORATIONS GREATER THAN 10MM. ONE SUCH PERFORATION HAS CREATED A CRACK ON THE FRAME JUST IN FRONT OF THE RIGHT REAR LOWER CONTROL ARM MOUNT. IF THIS VEHICLE WERE TO HIT A BAD ENOUGH BUMP OR POT HOLE, THERE EXISTS A POSSIBILITY THE FRAME COULD SNAP AND ALLOW THE CONTROL ARM TO BECOME FREE AND THE VEHICLE WOULD LOSE CONTROL

NHTSA complaint #11354353 — an unverified report by a vehicle owner.

SUSPENSION

I TOOK MY 2003 TOYOTA 4RUNNER INTO MY LOCAL MECHANIC TO DO MY ANNUAL STATE SAFETY INSPECTION AND THE MECHANIC INFORMED ME THE FRAME WAS TOO RUSTED TO PASS INSPECTION. FURTHERMORE, HE SAID THAT THE RUST WAS SO SEVERE IT HAD SEPARATED THE SUSPENSION FROM THE FRAME. HE TOLD ME IT WAS THE WORST FRAME RUST HE HAD EVER SEEN AND THAT THE CARS FRAME LOOKED LIKE IT WAS 20 YEARS OLDER THEN IT WAS. IT WAS TOTALLY RUSTED THROUGH IN SEVERAL SPOTS. I CALLED TOYOTA TO SEE IF THEY WOULD WORK WITH ME TO FIX THIS ISSUE AND THEY OFFERED NO HELP. ALL THE OTHER CARS BUILT ON THIS FRAME HAVE BEEN RECALLED, I'M NOT SURE WHY THIS ONE HASN'T BEEN.

NHTSA complaint #11350643 — an unverified report by a vehicle owner.