140 of the
1,219 complaints filed about the Toyota FJ Cruiser
are about the braking system —
11% of everything owners reported.
The worst model year for it is 2007.
Please consider opening or expanding an investigation into frame, underbody, brake-line, and suspension-mount corrosion affecting Toyota FJ Cruisers. I own a 2013 Toyota FJ Cruiser 4WD. A professional inspection found multiple fluid leaks, heavy rust, rusted exhaust, leaking rear shocks, and brake line/hose concerns. After reviewing the condition, the mechanic essentially declined to repair it and recommended scrapping the vehicle. The attached photos show conditions that appear safety-relevant: rust perforation through underbody structural metal near a bracket/crossmember area; severe corrosion around brake lines and fittings; widespread scaling near suspension and frame components; a leaking rear shock; and badly deteriorated exhaust connections. This is not just appearance rust. Also note the contrast between the observable condition of the vehicle versus the problems hidden beneath. This rust is clearly outpacing normal wear and tear. The safety risk is straightforward. At interstate speeds, a corroded brake line could fail during emergency braking. A weakened shock mount, suspension bracket, or crossmember could fail when the vehicle hits a pothole, uneven bridge plate, or highway debris. In dense, aggressive traffic, especially where vehicles travel 70+ mph, any sudden loss of braking, stability, or rear-end structural integrity could cause a spinout, rollover, or multi-vehicle crash. I understand Toyota has previously addressed severe corrosion on other truck platforms. I urge NHTSA to review whether the FJ Cruiser has a similar pattern of premature or excessive structural corrosion. Owners may not know the vehicle is unsafe until a mechanic refuses repair or a component fails. Please review consumer complaints, inspection photos, and corrosion-related failures before this becomes a fatal incident.
NHTSA complaint #11736593 — an unverified report by a vehicle owner.
I am the owner of a Toyota FJ Cruiser (Year:2007), VIN: [XXX] ]) equipped with the TRD High-Performance Brake Kit, which is under recall campaign C0R / NHTSA 12E046. I recently experienced a serious safety issue involving the front TRD brake crossover tube. While driving, I suddenly noticed a soft brake pedal and significant loss of braking power. I was unable to stop the vehicle properly and nearly crashed into another car at an intersection. I had to swerve at the last moment, which could have caused a more serious accident. Upon inspection, I found that brake fluid was leaking from the crossover tube—exactly the defect described in the TRD brake recall. This failure happened without warning, and my safety and the safety of others was clearly at risk. This is unacceptable for a safety recall. I am requesting immediate investigation, assistance, and a permanent solution. Toyota must ensure this part is properly redesigned and replaced, and that no vehicle is left on the road with this faulty setup. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)
NHTSA complaint #11666491 — an unverified report by a vehicle owner.
I recently purchased the used 2007 Toyota FJ with 101,000 miles. During maintenance and inspection, it was found that the fuel tank straps are rusted out and need to be replaced. The rear brake lines are rusted out and need to be replaced. The frame is severely rusted out and failing at the factory welds. I was referred to submit a report and investigate filing a class action lawsuit against the manufacturer for negligence, as this is apparently a known issue. I am hoping that the will reach someone that is able to help all the owners with the same issues as this should be recalled and repaired to prevent unnecessary injury or death. This is a huge financial burden for those expecting a quality vehicle that will be safe. Failing brakes, loose gas tanks and weakened frames are recipe for disaster.
NHTSA complaint #11504331 — an unverified report by a vehicle owner.
the brakes are constantly binding up due to rust and need replaced, recently ABS brake lines rusted off causing me to miss a stop sign, very dangerous, Upper rear control arm mount rusted and cracked completely off causing steering and braking problems and had to be replaced to even use this vehicle, , The front rack has been replaced due to excessive rust of lines and fittings, same with transmission cooler lines-rotted off...brake backing plates rotted off.. Even though I have had this undercoated and rust treated, the frame is rusting inside-out...frame braces, everything on the frame is rusted much more than one would expect, even in a salt state like Ohio....my safety was put at risk by faulty brakes, the frame is not safe under hard braking and may cause an accident, the dealer has seen this vehicle, a local independent says "get rid of it"...no warning lamps, just wild things happen with brakes, pulls left, pulls right, front, then back and this past time ...NONE!...only 111,000 miles.
NHTSA complaint #11503872 — an unverified report by a vehicle owner.
On the home my wife went to apply the brakes and she had no brake pressure. The pedal went all the way to the floor. Then several lights and a buzzer sound started, and she could not stop the car. She was able to pull up on the e-brake just before she drove completely into the intersection, where several cars were driving in both directions. The front end of car ended partially in the north bound lane of US MD-5. There was also a home at the end of the road that she could have also driven into. I researched on several forums where other owners have had the same issue and the dealership has been unable to diagnose the issue. No TSB or recall has been made, but the number of people that have had this issue, something should have been done. My 4-year-old daughter was in the car, and I could have lost both of them. People need to aware of this. I had no idea that a total brake failure was possible with these vehicles.
NHTSA complaint #11502784 — an unverified report by a vehicle owner.
I purchased the vehicle with a clean carfax on 12/2/2021 Flew from Phoenix to Dallas to pick it up. Drove the vehicle from Dallas to Phoenix. The Brakes malfunctioned on the drive home. Fortunately it was late at night and not many vehicles on the road. Took car to mechanic on 12/4/2021. The frame, brakes, suspension, exhaust and engine mounts had been sprayed over to cover severe rust and rot of the the frame and undercarriage. The vehicle cost 14k The repairs to be done 20k The vehicle is not roadworthy and has not been driven since ai got back to Phoenix. The dealership purposely didn’t disclose the frame or brake damage. The dealership sold this vehicle knowing it was for my daughter and 3 year old granddaughter
NHTSA complaint #11444119 — an unverified report by a vehicle owner.
Due to rust on my 2007 FJ Cruiser, I've had many unexpected expenses. I first was losing brake pressure and my brake lines had to be replaced after breaking when in a mechanic's shop. I've also replaced all four calipers, all the rusted pulleys on the engine, lower control arms that were so rusted that they had to be cut out, and hub assemblies for both front wheels. The hub assembly lead to a failed vehicle inspection for safety concerns. The exhaust pipe literally broke apart near the rear frame crossmember and was sitting on it, so had to be replaced. The exhaust manifold rusted apart and separated from the engine block, leading to dangerous fumes in the engine bay and horrible gas mileage. The O2 sensors were rusted in place and giving poor readings and had to be replaced. Turning the steering wheel became difficult and that was due to being extremely rusty, so it had to be replaced. Shifter cable and PRNDL switch had to be replaced due to not shifting into drive or lower gears. The front differential drain plug was so rusted that the dealership would not attempt to remove it. Now there are holes rusted through the body mount brackets, as well as the passenger side floor. The cargo area's floor where the charcoal EVAP canister connects to the vehicle has completely rusted through, and one of the subframe brackets rusted so badly that it was taken off by hand. Both subframe brackets need to be replaced. The rear control arm mounts are very thin due to extreme rust. My mechanic is now replacing coolant lines because they have rusted through and started to leak, and gas tank straps which were on the verge of failing.
NHTSA complaint #11419802 — an unverified report by a vehicle owner.
UPON HARD BRAKING, IF VEHICLE HITS A BUMP, POTHOLE, UNEVEN ROAD SURFACE, ETC, THE ABS KICKS IN MAKING IT ALMOST IMPOSSIBLE TO STOP UNLESS I COMPLETELY RELEASE THE BRAKES THUS REQUIRING ME TO SLAM ON IT HARD TO PREVENT REAR ENDING ANOTHER OBJECT.
NHTSA complaint #11415809 — an unverified report by a vehicle owner.
RUST TO THE FRAME OF THE CAR NOT CONSUMMATE WITH THE AGE OF THE VEHICLE, RUST TO THE STRAPS THAT SECURE THE FUEL TANK. POINTS THAT AFFIX THE BRAKE LINES TO THE VEHICLE FRAME HAVE RUSTED TO THE POINT THEY'RE NO LONGER AFFIXED TO THE FRAME. THE RATE AT WHICH RUST GESTATES ON THIS VEHICLE (AND I AM MUCH MORE ATTENTIVE THAN THE TYPICAL CONSUMER) IS UNSAFE AND WILL CONTINUE TO CREATE UNSAFE CONDITIONS AS THESE VEHICLES RAPIDLY DETERIORATE. THE RUST PREVENTION METHODS USED BY THE FACTORY ARE ENTIRELY INADEQUATE.
NHTSA complaint #11403897 — an unverified report by a vehicle owner.
SEVERE RUST ISSUES. ENTIRE REAR DIFFERENTIAL REQUIRED REPLACEMENT. ALL POWER STEERING AND AUTOMATIC TRANSMISSION LINES NEEDED REPLACEMENT, FUEL LINES ARE NEXT FUEL TANK STRAPS RUSTED AND BROKE OFF, TANK FELL DOWN. BRAKE PAD PINS REQUIRED CUTTING OFF. PROTECTION PLATES RUSTED OFF. EXHAUST SYSTEM COMPONENTS REQUIRED REPLACEMENT DUE TO RUST. ENTIRE FRAME AND ENGINE COMPARTMENT COVERED IN RUST. ALL THESE ITEMS HAVE CAUSED MULTIPLE SAFETY ISSUES. MULTIPLE STRAPS AND CONNECTIONS FOR VARIOUS COMPONENTS ARE NO LONGER USABLE DUE TO RUST.
NHTSA complaint #11375036 — an unverified report by a vehicle owner.
2008 TOYOTA FJ CRUISER FRAME ROTTING FROM INSIDE AND OUT. ALL SUSPENSION COMPONENTS HAVE BEEN REPLACED DUE PARTS FAILING BECAUSE OF CORROSION THAT BLED OVER FROM THE FRAME TO INCLUDE BOTH FRONT STEERING KNUCKLES, TWO PARTS THAT ONLY EVER GET REPLACED IN THE EVENT OF AN ACCIDENT. SEVERAL FRAME SUPPORTS HAVE CORRODED FROM THE INSIDE OUT AND ARE FLAKING OFF. BRAKE COMPONENTS THAT RUN ALONG THE FRAME HAVE CORRODED FROM THE FRAME TO THE BRACKET THAT HOLDS THEM TO THE LINES THEMSELVES. CAUSE A SLOW BRAKE LEAK OVER TIME THAT EVENTUALLY RESULTED IN A DANGEROUS NEAR ACCIDENT SITUATION THAT WAS CAUSED BY COMPLETE IMMEDIATE LACK OF BRAKE PRESSURE. EVASIVE DRIVING AND A SOUND MIND AVOIDED A LEGITIMATE ACCIDENT, HAD TO TOW THE TRUCK TO A SHOP. UNSAFE TO DRIVE. FRAME WILL NOT HOLD UP IN AN ACCIDENT. 12 YEAR OLD FRAME SHOULD NOT BE ANYWHERE NEAR THIS CONDITION. DUE TO OVERSIGHTS AT THE MANUFACTURER THIS FRAME IS NOW CORRODING FROM THE INSIDE OUT.
NHTSA complaint #11341612 — an unverified report by a vehicle owner.
VEHICLE WAS DRIVING IN TRAFFIC AND MULTIPLE HAZARD LIGHTS CAME ON, ALARM CAME ON, AND AS DRIVER ATTEMPTED TO SLOW DOWN BRAKE PEDAL WENT TO THE FLOOR AND DOWNSHIFTING WITH EMERGENCY BRAKE USED TO STOP IN MIDDLE OF INTERSECTION.VISUAL INSPECTION REVEALED NO BRAKE FLUID IN MASTER CYLINDER RESERVOIR AND LEAKING BRAKE FLUID ON DRIVERS REAR BRAKE CYLINDER.PICS ATTACHED.PRIOR REPORTS APPEAR OF THIS FJCRUISER ISSUE BUT ONLY TACOMA VEHICLES RECALLED.I AM CONTACTING MY LEWISVILLE TOYOTA WHERE I PURCHASED VEHICLE.
NHTSA complaint #11340102 — an unverified report by a vehicle owner.
SEVER RUSTING OF FRAME, BREAK AND SUSPENSION COMPONENTS AND BRACKETS. THIS 2008 TOYOTA FJ CRUISER IS QUICKLY BECOMING A SAFETY HAZARD ON THE ROADS. I HAVE A 92 SABB AND A 93 VW THAT DON'T HAVE HAVE THE RUST ISSUES THIS TOYOTA HAS. TOYOTA SHOULD HAVE RECALLED THE FJ CRUISERS FOR FAULTY FRAMES AND UNDERCARRIAGE LONG AGO.
NHTSA complaint #11306740 — an unverified report by a vehicle owner.
I HAVE HAD TWO BRAKE LINES BURST IN THE PAST YEAR DUE TO RUST. BOTH TIMES I WAS LUCKY TO NOT HAVE BEEN ON THE INTERSTATE AND WAS TRAVELING AT A LOW SPEED. BOTH HAVE BEEN THE BACK BRAKE LINES. THIS RUST SITUATION WITH THE FJ'S IS UNACCEPTABLE AND DANGEROUS! TOYOTA SHOULD BE HELD ACCOUNTABLE AND THE SITUATION NEEDS TO BE ADDRESSED BEFORE A PERSON IS KILLED OR SERIOUSLY INJURED.
NHTSA complaint #11297827 — an unverified report by a vehicle owner.
EXCESSIVE AMOUNT OF RUST FOR MILEAGE OF CAR 156K AS OF WRITING FRAME IS FLAKING/SCALING EVEN AFTER APPLICATION OF POR-15 TO TRY AND SALVAGE THE FRAME TO MAKE IT LAST A WHILE LONGER. REPLACEMENT OF TANK STRAPS AT 120K DUE TO FAILURE FROM RUST. CAR WILL BECOME UNSAFE TO DRIVE IN A SHORT PERIOD THIS SEEMS TO BE A VERY COMMON ISSUE WITH THIS FRAME/YEAR AREA AS TOYOTA ALREADY HAS REPLACED THE TACOMA FRAMES THAT WERE RUSTING/ROTTING THE SAME WAY.
NHTSA complaint #11296883 — an unverified report by a vehicle owner.
DURING 2019-2020 STATE INSPECTION OF 2007 FJ CRUISER WITH 78000 MILES BY DEALER WAS TOLD THAT FRAME IS SO RUSTED THAT IT PROBABLY WOULD NOT PASS THE NEXT INSPECTION. EXPLANATION GIVEN WAS THAT TOYOTA DOES NOT MAKE THEIR FRAMES AS THICK AS OTHER MAKES. THIS VEHICLE WAS USED AS A DAILY DRIVER, NOT MUCH OFF-ROAD AND NO SERIOUS OFF-ROADING. I WORK FROM HOME, SO MOST YEARS LESS THAN 5000 MILES DRIVEN. ALSO HAVE HAD TO REPLACE FRONT BRAKE CALIPERS FOR THE PAST 3 YEARS.
NHTSA complaint #11291290 — an unverified report by a vehicle owner.
BOUGHT MY FJ NEW IN 2007.WHEN I DID I ASKED IF THEY HAD RUSTY JONES OR UNDERCOATING AND WAS TOLD WITH THE NEW ALLOYS I DIDNT NEED IT. 3 WEEKS AGO I WAS HAVING MY MECHANIC CHECK THE BRAKES AND HE CALLED ME DOWN TO SHOW ME A BREAK IN THE FRAME CONNECTING TO THE BODY.THANKFULLY HE FOUND IT BECAUSE I WAS SUPPOSED TO GO TO BOSTON THE NEXT DAY. THE TRUCK ONLY HAS 139,000 MILES ON IT AND THE FRAME IS COMPLETELY RUSTED OUT SO ITS NOT SAFE TO DRIVE.I BROUGHT IT TO THE DEALER I PURCHASED IT FROM AND 2 REPS CAME DOWN FROM NH TO LOOK AT WHO BASICALLY TOLD ME I HAD A GOOD RIDE WITH IT AND THEY WOULD DO NOTHING.I THEN CALLED TOYOTA CEC AND WAS TOLD THE SAME. I BROUGHT TO A WELDER WHO SPECIALIZES IN THIS TYPE OF WORK AND WAS TOLD 5000+ IN LABOR ALONE AND THATS WITHOUT SEEING UNDER THE GAS TANK SO HE SAID IT WOULDNT BE WORTH IT AS HE BANGED OF THE RUST IN OTHER SPOTS AND THERE WAS NO METAL TO WELD TO LEFT.BRAKE AND FUEL LINES ARE SWELLED FROM THE RUSTY METAL TUBING.I CONSIDER MYSELF LUCKY AS I OFTEN TAKE MY GRANDKIDS IN THE FJ. SO NOW IM LEFT WITH MY OTHER FJ THAT I BOUGHT NEW IN 2008 WHICH IS OK UNDERNEATH.THE ISSUE IS WITH ALL THE 2007 FJ FRAMES LIKE THEIR TUNDRAS AND TACOMAS. I HAVE OPENED A CASE WITH TOYOTA BUT THERE ARE SO MANY THERE SHOULD BE A RECALL AS THESE ARE UNSAFE TO DRIVE.THE BODY IS READY TO COLLAPSE ON THE FRAME. I WAS TOLD PRIVATELY THAT TOYOTA CHOOSES TO IGNORE THE ISSUE AS THEY NO LONGER MAKE THE FJS BUT STILL SELL TACOMAS AND TUNDRAS. ## VIN PASSED ## 2007 TOYOTA FJ CRUISER ##
NHTSA complaint #11291333 — an unverified report by a vehicle owner.
UNDERCARRIAGE OF 2010 FJ CRUISER RUSTED. FRONT BRAKE LINES RUSTED OUT AND I LOST FLUID. COULD HAVE GOTTEN KILLED. THANK GOD ONLY GOING 25 MPH NEAR HOME
NHTSA complaint #11281681 — an unverified report by a vehicle owner.