2005 Toyota 4RUNNER body problems

STRUCTURE:BODY

I have a 2005 Toyota 4runner with frame rust that has caused everything under my 4runner to rust. Toyota knows these frames have problems with rust and corrosion and have done nothing, I am far from being the only one with this complaint or problem. It is up for inspection anytime. I have taken it to get work done at shops and been turned away because of the amount of rust on all bolts, lines, all metal under truck causing it to be a liability. I cant even get my skid plates off to fully address the issue. The metal is starting to split on the main frame by the tire, it is rotting from inside. Rust has always been there but last couple years has gotten really bad. So much rust my gas tank strap has broken but so much rust I cant get the skid plate off to fix it.

NHTSA complaint #11737968 — an unverified report by a vehicle owner.

STRUCTURE

The contact owns a 2005 Toyota 4Runner. The contact stated that while driving at an undisclosed speed, the vehicle briefly hesitated and was unable to accelerate, prompting the contact to discontinue driving the vehicle. The check engine warning light was illuminated. The vehicle was taken to an independent mechanic, who diagnosed a failure with the catalytic converter. The contact was also made aware that the mechanic discovered excessive corrosion covering the entire subframe of the vehicle. The contact was advised not to drive the vehicle. The vehicle was not repaired. The manufacturer was notified of the failure but provided no assistance. The failure mileage was 205,000.

NHTSA complaint #11678278 — an unverified report by a vehicle owner.

STRUCTURE:BODY

- The undercarriage and frame have had premature rusting for years. The car is otherwise in excellent condition due to my care of it over the last 20 years. 5 years ago, a service person at my local Toyota dealership said, "I'm really disappointed in Toyota, I've never seen rust like this." I have now recently been told by a local service shop that it's time to get a new car. The lines are all corroded for the power steering, etc, and he was unable to even "touch them," and said that the rust issue is no longer safe, and we shouldn't drive far from home. - We are now unable to drive the car much, as we live in the country and have far communities. With a [XXX] , we are unwilling to drive the car over 45 mph, or more than 10 miles for fear of an accident after reading about the manufacturing defect in this model of the 4-Runner. - It has not been inspected by the above stated people. - no warnings, I would not have know the vehicle had such severe premature rusting issues if it weren't for a service person telling me such. -My vehicle has under 140k miles on it, and I've taken exceptional care of it over the past 20 years. I could have sold it for 10k given its condition, and low mileage, but it is now likely worth nothing given the manufacturing defect which caused premature rusting. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA complaint #11672178 — an unverified report by a vehicle owner.

STRUCTURE:BODY

When I first saw the pictures on the internet, I noticed that the front underside appeared to have rust issues. (Frontal shot) I contacted that sales person and he blew me off when I requested photos of the underbody. After several attempts, he finally sent a couple of pictures. The pictures obviously did not show the major rust issues as I have provided. The pictures were carefully fabricated not to show the major rust issues. It was apparent that the vehicle was taken off the internet while they hid the rusty underbody by applying some coating. A short time later, the dealership reposted the vehicle on their website. The vehicle was not properly advertised as having this major rust issue. I asked the salesman if his family was driving the vehicle, would he feel safe. He replied, "Absolutely". With this said, I decided to purchase the vehicle. Also, my signature is not on the "We owe". Also, the vehicle has an exhaust leak from the manifold area. It makes a loud ticking noise. This is going to cost approximately $1,500 to fix. The air conditioner is not blowing cold and either has a leak or in need of freon. This is another repair out of my pocket. This is what kind of pre-owned vehicle they sold me. This vehicle should have never been listed for sale.

NHTSA complaint #11669643 — an unverified report by a vehicle owner.

STRUCTURE:BODY

Frame rot. The frame on the 4Runner is a known problem for excessive rot. My frame is shot. There is no reason a frame on a 2005 should be rotted. I was advised by my mechanic that my frame is dangerously close to snapping in half. This needs fixed by Toyota!

NHTSA complaint #11663092 — an unverified report by a vehicle owner.

STRUCTURE:BODY

Under frame is rusted. The area between the doors in the passenger side is gone. only the top face of the member is present.

NHTSA complaint #11637811 — an unverified report by a vehicle owner.

STRUCTURE:BODY

Frame has very severe rust and has started to come part in places. Soon vehicle will no longer be road worthy.

NHTSA complaint #11609376 — an unverified report by a vehicle owner.

STRUCTURE:FRAME AND MEMBERS

The contact owns a 2005 Toyota 4Runner. The contact stated that the subframe was rusted. The TPMS warning light was illuminated. The vehicle was taken to an independent mechanic, who repaired the TPMS, but the failure persisted. The vehicle was taken to the local dealer, where it was diagnosed that the frame was rusted and recommended that the vehicle no longer be driven. The mechanic referred the contact to the manufacturer. The vehicle was not repaired. The manufacturer was contacted and referred the contact to the NHTSA Hotline. The failure mileage was approximately 200,948.

NHTSA complaint #11560604 — an unverified report by a vehicle owner.

STRUCTURE:BODY

Frame of the vehicle is showing rust corrosion. The frame are the same as the tacomas that were released the same year. The tacomas were granted frame replacement by Toyota but 4Runners weren’t. Noticed a lot of other 4th generation 4Runners are having the same issues.

NHTSA complaint #11553471 — an unverified report by a vehicle owner.

STRUCTURE

The contact owns a 2005 Toyota 4Runner. The contact stated while the vehicle was at the independent mechanic for servicing, and he was informed that the sub frame was severely corroded. The dealer was notified of the failure and referred the contact to the manufacturer. The manufacturer was notified of the failure and referred the contact to the NHTSA Hotline for assistance. The vehicle was not repaired. The failure mileage was approximately 166,000.

NHTSA complaint #11520258 — an unverified report by a vehicle owner.

STRUCTURE:BODY

Frame on 2005 Toyota 4Runner has excessive rust due to Toyota’s negligence on frame production. I can make it available if needed. My safety is 100% compromised, had my mechanic not have told me of the issue, I would have kept driving the vehicle and the suspension could have detached from the frame at any point. The problem has been confirmed by my independent service center South Lake Automotive. It has not been inspected by police, manufacturer or other. There was no warning prior to the failure. Had I not had it pointed out as an issue, I would never have known it was an issue.

NHTSA complaint #11488093 — an unverified report by a vehicle owner.

STRUCTURE:BODY

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 complaint #11483876 — an unverified report by a vehicle owner.

STRUCTURE:BODY

Frame of the vehicle is rusting from the inside out. Upon inspection, holes in the frame are found, with many more hidden from sight. This is a disaster waiting to happen. This puts the driver and anyone else on the road at extreme risk if the frame breaks while driving. This problem is well documented with Toyota, and they have previously replaced Tacoma, Sequoia, and Tundra frames, but not 4runners. Everyone is at risk with these frames, even if it does not appear so. My frame looked solid until I began hitting it with a hammer and screwdriver and breaking away very weak spots of metal.

NHTSA complaint #11472212 — an unverified report by a vehicle owner.

STRUCTURE:BODY

I took my vehicle into the Toyota Dealer after mechanic told my frame was rusting. The dealership confirm the frame is rusted. The frame of the vehicle should not be rusting out.

NHTSA complaint #11466079 — an unverified report by a vehicle owner.

STRUCTURE:BODY

The rear control arm broke while I was driving causing me to swerve uncontrollably and almost causing a collision

NHTSA complaint #11457890 — an unverified report by a vehicle owner.

STRUCTURE:BODY

I have a 2005 4Runner with significantly rusted out frame that makes me worried about safety of driving it. I feel the amount of corrosion present is way beyond what I would expect for that year of vehicle

NHTSA complaint #11451105 — an unverified report by a vehicle owner.

STRUCTURE:BODY

The frame broke loose from the rear sway bar due to excessive rust while I was driving it. My 4Runner is an 05 and has the same frame as the Tacomas of the same year, except with no recall. I believe it is wrong to recall the Tacoma frame and not the same 4Runner frame. It is available for inspection. The car wanted to loose control anytime the accelerator was pressed or released. The problem has been an issue for many 4Runner owners of similar years. There was no warning to this occurrence.

NHTSA complaint #11442604 — an unverified report by a vehicle owner.

STRUCTURE:BODY

My 2005 4Runner frame is completed covered in rust and is corroding. Several places on the frame is rotting away.

NHTSA complaint #11441407 — an unverified report by a vehicle owner.

STRUCTURE:BODY

Extreme rusting on frame and all parts under the carriage. Vehicle suspension and all moving parts underneath could fail or fall apart causing major accident or death to me or other vehicle.

NHTSA complaint #11441149 — an unverified report by a vehicle owner.

STRUCTURE

The contact owns a 2005 Toyota 4Runner. The contact stated that after purchasing the vehicle, it was discovered that the subframe of the vehicle was severely rusted. The cause of the failure was not determined. The manufacturer and local dealer were notified of the failure. The failure mileage was 212,000.

NHTSA complaint #11440902 — an unverified report by a vehicle owner.

STRUCTURE:BODY

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 complaint #11435632 — an unverified report by a vehicle owner.

STRUCTURE:BODY

Upon recent inspection of my vehicle, it was noted that the frame is severely corroded and rusted to the point where collapse or breaking of the frame is possible while driving. Apprently the frame was not properly treated for rust protection and can now be unsafe for driving. Enclosed are pictures of the rusted frame.

NHTSA complaint #11431129 — an unverified report by a vehicle owner.

STRUCTURE:BODY

Frame and rear differential rust- extreme

NHTSA complaint #11429160 — an unverified report by a vehicle owner.

STRUCTURE:BODY

Extreme frame rusting completely thru at the point of being unsafe and unable to put the truck on a lift for any repairs. A number of SAE mechanics warned me about driving this truck due to the extreme frame rusting. Sections almost completely separating apart. I have rust proofed and undercoated the under carriage at least three times. Toyota should make good on their negligence to properly rust coat their frames at times of manufacturing.

NHTSA complaint #11429191 — an unverified report by a vehicle owner.

STRUCTURE:BODY

Really bad rame rust with holes through frame and frame components. I have pictures showing it’s the entire frame, not just the few spots. I had a shop replace the gas tank straps and when I picked it up they told me/warned me the frame had really bad rust. Have read about others having same or worse problems with chassis rust with this generation of 4Runners.

NHTSA complaint #11429111 — an unverified report by a vehicle owner.

STRUCTURE:BODY

I would like to complain regarding my 2005 4Runner. Went to have the fluid changed at a dealership in the early part of July 2021 and they could not perform the service due to excessive underbody rust and corrosion . Therefore the I will have to find a service that can remove the corrosion to be able to have the shocks change, differential fluid change and to check and perform service on the brakes. The corrosion is starting to eat at the key components of the vehicle to the point where I may not be able to drive. Steering will be restricted and brakes will malfunction if they cannot get to the remove the areas to service the vehicle.

NHTSA complaint #11425991 — an unverified report by a vehicle owner.

STRUCTURE:BODY

My frame is starting to rust very terribly no matter what i do to maintain it. The radiator support is completely rotted out and the rear part of the frame is getting worse by the month. This will cause a major injury in the case of an accident or the frame will break off while driving

NHTSA complaint #11425039 — an unverified report by a vehicle owner.

STRUCTURE:BODY

Excessive frame corrosion. Mounting bracket that connects the lateral arm to the frame failed due to the deterioration of the frame. The rear axle is no longer perpendicular to the length of the car. I am experiencing a symmetric acceleration and braking performance and unpredictable steering.

NHTSA complaint #11424499 — an unverified report by a vehicle owner.

STRUCTURE:BODY

I had my 2005 Toyota 4runner Limited serviced today. The mechanic will not work on the vehicle due to excessive rust and holes in the frame. The vehicle looks immaculate on the inside and out, but due to the corrosion underneath I am being advised to junk the vehicle as it is unsafe to drive.

NHTSA complaint #11421978 — an unverified report by a vehicle owner.