380 of the
6,482 complaints filed about the Toyota 4RUNNER
are about the engine —
6% of everything owners reported.
The worst model year for it is 1990.
I am reporting what I believe is a design defect involving the Secondary Air Injection (SAI) System on my 2014 Toyota 4Runner. My vehicle illuminated the Check Engine Light and stored Diagnostic Trouble Code P2440 (Secondary Air Injection System Switching Valve Stuck Open). During my inspection, I found that the factory-installed foam air pump filter had completely deteriorated and was missing. The filter appears to have disintegrated over time rather than being removed during maintenance. The filter is intended to prevent contaminants from entering the Secondary Air Injection pump and switching valves. Once it deteriorates, debris can enter the system, potentially contaminating the switching valve and causing the P2440 fault. This failure caused my vehicle to enter reduced-power ("limp") mode, resulting in a significant loss of engine power and acceleration. This created a safety hazard because the vehicle could not accelerate normally while driving, increasing the risk when merging into traffic, crossing intersections, or traveling at highway speeds. Toyota has discontinued the original replacement foam filter, preventing owners from restoring the system with the factory-designed component. Numerous other owners have reported similar failures involving deteriorated or missing foam filters, P2440/P2442 diagnostic codes, and costly Secondary Air Injection System repairs. I respectfully request that NHTSA investigate whether deterioration of this factory foam filter is a design or material defect that allows contamination of the Secondary Air Injection System and can lead to limp mode and reduced engine performance. If confirmed, Toyota should provide an appropriate remedy, such as redesigned components or an extended warranty for affected vehicles. This failure appears to result from deterioration of an original factory component rather than improper maintenance or normal wear and presents a potential safety concern for other Toyota 4Runner owners.
NHTSA complaint #11753646 — an unverified report by a vehicle owner.
We were traveling north on hwy 23 in southern Minnesota pulling a 5000 lb trailer in the rain and it was windy. When the road split to 4 lane I stepped on the gas to speed up from 55 to 65 and the vehicle studderd and lost all power. Many warning lights cam on and I think it said stop within .3 miles. We pulled to the side of the road and basically coasted to a stop. It was on hybrid power. We called the nearest Toyota dealership and they suggested restarting the vehicle and see if we could make it to them. The engine did restart still with all the warnings on and we were able to drive it to the dealer being really gentle with the throttle. They pulled codes and it was intake related. They removed the air filter and it was dripping wet. The raised intake ingests water when it's raining and if it's working hard enough it pulls it through the filter into the intake and causes the vehicle to suddenly lose power which could possibly cause a accident. I am also concerned about water pulling dirt with it into the motor and causing damage. I have driven the vehicle in the rain since this happened but not pulling a trailer and really working it and so far it hasn't shut down on me yet but I've pulled the filter and it was wet. I have brought this issue to my dealer but they said they are not aware of a problem. I will attach a video of the wet filter I pulled from the air box after driving in a rain storm and a video of the warning lights that appeared. I don't think the dealership I took it too has any records of it because it was just after closing and they used a handheld scanner. They just dried our filter off and cleared the codes.
NHTSA complaint #11745715 — an unverified report by a vehicle owner.
The contact owns a 2025 Toyota 4Runner. The vehicle lost motive power while attempting to access the freeway on three occasions. The reduced power mode message was displayed. The vehicle was taken to the local dealer, and initially they were unable to determine the failure. The vehicle was taken to the local dealer again, where it was diagnosed that the sensor needed to be cleaned. The vehicle was repaired, but the failure persisted. The manufacturer was contacted, and a case was open. The failure mileage was approximately 11,000.
NHTSA complaint #11737053 — an unverified report by a vehicle owner.
The dealership Direct Motor, located in Manassas, Virginia, sold me this car in poor condition. On Sunday the 22nd, I picked up the car around 10 PM. They didn't show me any information about the car. When I picked it up, I saw that the front bumper and rear door were damaged, and the airbag lights were on, which is dangerous. I returned the car first thing Monday morning and asked them to exchange it. They refused. I asked for my money back, which is $3,000, and they refused again. Then I went back on Wednesday and filled out a form explaining why I returned the car. They said they would return my money, but now they're not responding. They're trying to scam me.
NHTSA complaint #11727554 — an unverified report by a vehicle owner.
TOYOTA 4RUNNER 2013 VIN# [XXX] LP# XXX The gas needle will be above the half (middle line), and the fuel range on top of the dash would read anywhere from 160-213 miles, going 45 mph up a hill or 70 mph on the freeway, all of a sudden starts to stall and completely shut off while still driving. I would then only have a few seconds to try to pull over due to losing all power, and not being able to shift into neutral because it's a push/start button. The car will only turn back on after putting some gas into it, so I make sure to never let the gas needle go below the middle line or have the gas range reading go below anything around 160-200 miles since the vehicle has shut down at a different amount each time, and there's been multiple times. Also, the fuel level needle never matches with how many miles is shown on the range, displaying inaccurate readings. It has poor acceleration, poor mileage, and now making a loud whining noise that is heard from outside the vehicle near gas tank. I have tried looking up the VIN and it does not show that it falls under the recall, despite it having all the symptoms of a faulty fuel pump/sending unit. I love my 4Runner but I am in fear for my life whenever I drive it and not showing accurate fuel levels. I pray that nobody runs into me if the vehicle stalls out in the roadway, while going 30-80 mph (it has done it on regular roads and on the highway). There are no warning lights or check engine light. It's at about 208,000 miles, with the issue slowly getting worse over time. I am requesting for it to be inspected free of charge, as well as getting the necessary repairs that the recall is for free of charge. [XXX] [XXX] [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)
NHTSA complaint #11700686 — an unverified report by a vehicle owner.
I am writing to formally report a concerning issue with my 2022 Toyota 4Runner, which currently has approximately 22,000 miles. The vehicle is regularly serviced at a certified oil change facility, and during routine use, I noticed a puddle of oil forming in my driveway. Upon contacting the service center, I was advised to bring the vehicle in for inspection. The technician identified a crack in the OEM plastic oil filter housing, which was causing engine oil to leak. I was informed that this is a known issue the technician has encountered on multiple Toyota vehicles equipped with the same plastic housing. To resolve the issue, I purchased a replacement OEM aluminum oil filter housing, which the technician installed. Since the replacement, the oil leak has ceased, and there have been no further incidents. I am concerned that the original plastic oil filter housing may be defective or prone to premature failure, potentially leading to engine damage or safety hazards. I respectfully request that this issue be investigated and considered for a recall or service bulletin, as it may affect other Toyota owners.
NHTSA complaint #11689475 — an unverified report by a vehicle owner.
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.
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.
My transmission went off with no warnings and my vehicle has been serviced at the Toyota dealer since I bought it and they never mentioned to me there was an issue with my transmission which is very odd. So I was wondering is this is normal or if there others owners with the same problem. Now I don’t have a vehicle because the transmission is in back order and I can’t even get a rental car because it wasn’t an accident or a recall. So I would like for you to look into this issue for this Toyota model.
NHTSA complaint #11660130 — an unverified report by a vehicle owner.
Throttle has a lag when depressing gas pedal (occasionally a dead petal symptom) research indicates a TSB T-SB-0166-10 exist that relates to this issue. Lack of Toyota dealer assistance with this issue when contacted (Toyota of Round Rock Texas 78664) This issues is a safety concern when operating vehicle due to lack of throttle response when accelerating into traffic. When issue occurs, vehicle "stalls" and creates a dangerous situation that eventually will result is an accident.
NHTSA complaint #11649210 — an unverified report by a vehicle owner.
My vehicle is rear-ended by a large earth mover branded as a Kenworth. My vehicle was then pushed into another. After the initial impact, my engine went racing above 5,000 RPM. It was disengaged from the transmission. I switched my car into neutral, shut my car off and the engine was no longer racing when I restarted the car. Because of an engine racing, I am concerned about the potential that somebody's transmission would be engaged and it could cause serious further injury.
NHTSA complaint #11648905 — an unverified report by a vehicle owner.
My exhaust pipe rusted apart after the muffler causing the hot exhaust to expel upward and melt a rubber grommet on the floor. Then it proceeded to shoot into cargo area, melting the carpet backing and Styrofoam pad and insulation under the cargo area carpeting. This happened on an 11 hour road trip with the cargo area full of vacation stuff. I'm concerned about this being a potential fire and carbon monoxide issue.
NHTSA complaint #11629264 — an unverified report by a vehicle owner.
The contact owns a 2015 Toyota 4Runner. The contact stated that on four occasions while diving at various speeds, the vehicle stalled. The vehicle was restarted after approximately 10 minutes after each failure. The vehicle was not diagnosed or repaired. The manufacturer was notified of the failure. The failure mileage was approximately 143,400.
NHTSA complaint #11620980 — an unverified report by a vehicle owner.
Make: Toyota Model: 4Runner Year: 2013 Mileage: 76,200 Description of Incident While driving on [XXX] at night, the vehicle experienced a sudden and catastrophic engine failure, leaving it immobilized in the middle of the highway. This presented an immediate and severe safety risk to both the vehicle occupants and other motorists. The failure was later determined to be caused by a malfunction in the Variable Valve Timing (VVT) oil control system, specifically an Exhaust Cam Gear failure. This led to a broken timing chain and subsequent engine failure. Inspection and Diagnosis The vehicle was inspected by an authorized Toyota Dealer in Florence, SC. They confirmed the failure of the oil control system and recommended a complete engine replacement, estimating costs over $5,000. Broader Implications and Potential Safety Hazard Further investigation, including consultations with multiple Toyota technicians, review of technical discussions on various platforms, and examination of online 4Runner forums, suggests that this issue is not isolated. Failures of the exhaust cam gear and problems with the VVT Oil Control System appear to be common in the Toyota 1GR-FE Engine and other engines equipped with this system. It's noteworthy that Toyota issued a voluntary recall in 2014 (Safety Recall 13V-395, TM-TC-14021) for Lexus vehicles with similar issues. However, this recall does not appear to cover the 2013 1GR-FE 4Runner engine, despite the apparent similarity in potential failure modes. Safety Concerns This issue presents a significant safety hazard: Sudden engine failure at highway speeds can lead to loss of vehicle control. Unexpected vehicle immobilization, especially at night or in high-traffic areas, poses a severe collision risk. The apparent widespread nature of this issue suggests that many vehicles may be at risk of similar failures. Urgency for Action Given the severity of the potential outcomes and the ap INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)
NHTSA complaint #11605962 — an unverified report by a vehicle owner.
We purchased our vehicle new September 2023 from a Toyota dealership. Engine oil dipstick Toyota part 15301-50140 was installed in vehicle and was verified by 50140 stamped on dipstick. I wanted an extra oil dipstick so ordered a replacement through Toyota. The original dipstick part 15301-50140 is no longer available and has been superseded by Toyota part 15301-0P060. I ordered the new dipstick part number and received it from Toyota. It is verified by 0P060 stamped on the dipstick. The safety concern is the two dipsticks are not the same length and each one requires a different quantity of engine oil to reach the Full mark. The new dipstick -0P060 is 1/2 inch shorter than the old, no longer available dipstick -50140. Most importantly the Low and Full marks are also both 1/2 inch higher up or closer to dipstick handle on the new dipstick than the old one. It takes approximately 0.9 quart more of engine oil to reach Full on the new dipstick than on the old one. One of these dipsticks is correct for my vehicle and one is not. The original dipstick is no longer available and the new dipstick is not the same as the original. The difference of 0.9 quart more or less of oil in the engine is significant and important. Too much or too little oil can damage an engine or contribute to a shorter engine life. Both of these dipsticks cannot be correct for our vehicle. I have talked to the Service Managers at two Toyota Dealerships and they do not have an answer for why these dipsticks are different. I have spoken to Parts Department people at two additional Toyota Dealerships, called Toyota Motor North America and no one has any idea why these dipsticks are different or which one I should be using. I also wrote a letter to Toyota Motor NA Headquarters over two months ago and have received no response to date. I have both dipsticks available for inspection. Toyota needs to let owners know if they should replace their old dipsticks or not on these vehicles.
NHTSA complaint #11603553 — an unverified report by a vehicle owner.
Two transfer case seals failed at 64,000 miles. Caused excessive oil to leak out of transfer case and onto the exhaust. Safety was put as risk by potential full failure of transfer case which can cause loss of power at speed or leaking oil on exhaust causing a fire. Problem was verified by Armstrong Automotive and repaired. No warning lights were present. Problem found after smelling burning oil and noticing smoking coming from underneath vehicle.
NHTSA complaint #11603235 — an unverified report by a vehicle owner.
The contact owns a 2022 Toyota 4Runner. The contact stated that while driving at an undisclosed speed on the freeway, the vehicle lost motive power. The 4WD error and various other unknown warning lights and messages were illuminated. The contact managed to pull over and stated that smoke was seen coming from underneath the hood and that once he opened the hood, there were flames coming from the airbox, and he pulled out the air filter. The contact stated that he managed to extinguish the fire. The fire department arrived after the fire was extinguished, and there was no report completed. The vehicle was then towed to a local dealer; however, the mechanic made the contact aware that the manufacturer would send out an inspector. The inspector made the contact aware of a faulty unknown sensor; however, the vehicle remained at the dealer awaiting further diagnosis and repairs. The manufacturer was made aware of the failure. The approximate failure mileage was 47,000.
NHTSA complaint #11509914 — an unverified report by a vehicle owner.
My gear shift became difficult to shift. As I was driving it, when I physically shifted to the Drive position, the display didn't confirm "D", but I could drive. As I was driving, the car shifted to Neutral without me shifting, but did not show "N" on the display. My car stopped accelerating and revved higher. This occurred as I was driving on the road around 45 mph. I could not tell on the display that I was not in Drive. I pulled over safely luckily. I Continued to try to get it to drive to get it to a dealership to look at. They reported it was PRNDL switch issue. TECH FOUND INTERNAL CORROSION IN TRANSMISSION RANGE SENSOR CREATING A PHYSICAL RESISTANCE IN SENSOR WHICH PREVENTED VEHICLE FROM PROPERLY INDICATING GEAR. TECH REPLACED TRANSMISSION RANGE SENSOR, ADJUSTED SENSORWITH TECHSTREAM DATA LIST, AND PERFORMED HEALTH CHECK This is not the first they have seen either. This would appear to be a common safety issue to drivers. I also had a difficult time confirming the car was in the Park "P" position. I believe this issue could have potentially affected the vehicle's ability to engage in park and stay in park, much like the issue with getting into Drive and staying in Drive.
NHTSA complaint #11501788 — an unverified report by a vehicle owner.
Vehicle radiator light came on, shortly thereafter (5-10 min) vehicle overheated. Waited for vehicle to cool down, then drove home. The following day drove the vehicle to dealership. After an inspection the dealer stated the heads are cracked and needed to be replaced. When I asked how this could happen to a car that is regularly serviced with only 90k miles his response was "the original heads were made of weaker metal, the replacement ones are upgraded. We haven't had any come-backs on the ones we've replaced". I then asked, well how many vehicles has this impacted? Sounds like this should be covered under a recall? His response "We've had quite a few in the past month or so, seems to be happening when vehicles get to the 70-80k range." Sounds to me like Mazda knew the heads were made from inferior products which is why they upgraded the part on newer models.
NHTSA complaint #11473715 — an unverified report by a vehicle owner.
The frame of the car has been rusting at a significant rate in the last 4 years. Mechanic identified major rust issues that would make the vehicle not safe in case of an accident.
NHTSA complaint #11463988 — an unverified report by a vehicle owner.