50 of the
1,219 complaints filed about the Toyota FJ Cruiser
are about the fuel system —
4% of everything owners reported.
The worst model year for it is 2007.
The rear fuel tank mounting strap rusted in half. After filling vehicle with fuel and driving 10 miles home, I noticed the skid plate hanging down that covers the fuel tank. The plastic skid plate started to crack from the weight of the tank. The design of the skid plate to the tank allows moisture and contaminants to reside between the two, rotting the straps. Thankfully I noticed this as if I had kept driving I fear the tank would have completely fallen out of the vehicle. I ordered new straps and hardware, but during the parts search I found many owners of the Toyota FJ, all years, are having the same problem. Apparently the straps are just mild steel and were not treated with any corrosion preventative from the factory. I feel they should have been at least stainless steel. Part numbers for the straps are 77602-35050 and 77601-35110. I'll have photos once the parts come in and I take the vehicle apart. Currently I have a floor jack holding up the tank. Also to clarify, the skid plate is mounted to the fuel tank straps. Once both straps let go, the fuel tank is coming out with the skid plate. The fuel tank is located in front of the rear axle, the vehicle would run over it's own fuel tank, at least until the engine shuts off.
NHTSA complaint #11700752 — an unverified report by a vehicle owner.
I was driving down the street after filling up my fuel tank. I drove approximately 1/2 mile when I heard a sound, felt a clunk and stopped immediately. My fuel tank was hanging down on the ground. I called AAA and requested a flatbed and to bring a strap. He did not bring a strap and when my truck arrived at the mechanic the fuel tank had completely separated from the vehicle. The other complaint I have is the rusted frame. I purchased this vehicle used. I did not notice that the tube before the rear axle which holds suspension supports to the frame were completely broken off and separated from the rusted out frame that has failed. It has been welding but the rusted frame is very difficult to weld to.
NHTSA complaint #11535659 — an unverified report by a vehicle owner.
Rust is inherently bad on these vehicles. The other day i heard a weird noise under my truck driving down the road. As if I flung a rock up and hit a spring or something. To my dismay, I noticed the fuel tank hanging. One of the straps rusted to the point that it broke allowing the fuel tank to droop.
NHTSA complaint #11508823 — 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.
Serviced 99% of the time at Toyota dealer. Within a week of having the vehicle serviced by the dealer, I noticed a rattling/banging. One gas strap had completely rusted through, and the other was hanging on by about a quarter inch of material. I always ask the dealer to inspect the frame due to the history of rust problems on FJs—they have never flagged anything but I inspect it as I can myself, but have no way to lift the vehicle up thoroughly. I also have the service fluid applied by Rust Check to prevent/inhibit deterioration. On a sidebar, this summer I was traveling on the interstate when the rear-most crossmember rusted out while I was using a hitch haul to move a dresser to South Carolina.
NHTSA complaint #11497287 — an unverified report by a vehicle owner.
I filled up my truck with gas. Upon driving to work I noticed a loud clank. I looked under the vehicle but it was dark and saw nothing obvious. I continued down the road and heard knocking only when braking hard. When examined in daylight, I could see that the Fuel Tank Support Strap (Rear) rusted thru and the weight of the tank/fuel caused it to shift toward and rub against the Drive Shaft. The loud clank I would hear was caused by the tank being struck by the Drive Shaft balancing weight. The more I research, the more I see others have experienced the same thing. I made it safe until I could procure parts and make the repair. I examined the area and the replaced straps. The rear strap is doomed to fail. The OEM part is painted but exposed in the left rear tire well. Basically, the strap is doomed to be sandblasted by road debris, salt, sand and plain old dirt. Photos and descriptions of others with similar problems are always in the same location. I feel Toyota should make the Straps from a better quality material not as susceptible to corrosive properties of Salt. This is a serious fuel tank issue. If there was a problem with the front strap the rear strap failure could have dropped the tank on the road. Will it take the death(s) of the occupants of affected vehicle should a fire or explosion occur for Toyota to step up and assume responsibility? Or maybe if the tank falls out of the vehicle and car that runs over it then it explodes and kills those occupants will get Toyota's attention? I have retained the failed part should it be needed at a future date for inspection, etc.
NHTSA complaint #11486939 — an unverified report by a vehicle owner.
My Toyota FJ Cruiser 2008 "FUEL PUMP" failed to indicate the amount of gasoline I had in the tank, the car completely stop working on the freeway while I was driving approximately at 70 MPH right in the fast lane, the car/motor just ugly shook and suddenly it stall/shut down... luckily the cars behind me were able to maneuver their cars and avoided a possible crash. I tried to start the car again and gave me some forward jumps until i got it off of the road. the gas panel indicator was still reading 1/2 filled tank but not gas inside tank...I called freeway service patrol (511) and they Offered me a gallon of gas, as i run out (they saved my day). i thought this was just one hit wonder problem but not the car has been getting me in trouble ever since now my wife drives it too, she or me assume there is still gas in the car and out of the blue i wind out carrying gas in a red gallon... i asked mechanics if they can replace but they said no easy - access to replace the pump is not well designed to extract the fuel pump and the floor mats on the car and the rear seat must be removed and some how the car will have some cosmetic damage... best is to lower the full gas tank from underneath but there is also a problem as the wire connector length are extremely short and they must be cut out and add extensions after replacing pump and may affect sensor lights... and repair for that is quite expensive. The car pump goes up when full tank but as gas is used needle stops at 1/2 mark and there is no way to tell if i have gas- I had experienced 8 time stalls, luckily no accidents - I found this online and called Toyota but they are unaware of this recall: "if stall pump fails, the engine can stall while driving, increasing the risk of a crash. Toyota will notify owners, and dealers will replace the fuel pump, free of charge. The recall began May 4, 2020. Owners may contact Toyota customer service at 1-888-270-9371" is it true?
NHTSA complaint #11457301 — an unverified report by a vehicle owner.
FJ Cruiser in Tennessee Was filling up gas tank and heard a noise under the car. I looked and noticed that the back of the gas tank was hanging down. After I got it home, I discovered that the rear fuel strap had broken due to rust. The front fuel strap was also extremely rusted and probably would have failed also
NHTSA complaint #11435597 — an unverified report by a vehicle owner.
Single Toyota 2010 FJ Cruiser Owner. Over the last 10/11 have been really diligent taking care of my truck, unfortunately due to what seems very poor quality steel or treatment of the frame and some parts when was build by Toyota, it has cause severe rust/rotten issue leading not only to significant safety concerns (broken gas tank straps and fuel lines) but also a significant amount of money spend treating the frame and part to prevent further corrosion that could\will eventually lead to complete failure.
NHTSA complaint #11432203 — an unverified report by a vehicle owner.
FUEL TANK STRAPS RUSTED, AS WELL AS MULTIPLE AREAS IN FRAME RUSTED FROM THE INSIDE OUT. ONCE VEHICLE WAS PUT ON A LIFT, MECHANIC SAID GAS TANK STRAPS NEEDED REPLACED AS WELL AS SOME REPAIR TO THE STRUCTURAL INTEGRITY OF THE FRAME.
NHTSA complaint #11408585 — 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.
WHILE VIEWING THE UNDERCARRIAGE OF THE VEHICLE I NOTICED EXCESSIVE FRAME AND STRUCTURAL RUST AND CORROSION ON A MAJORITY OF THE FRAME, SUSPENSION, FUEL TANK STRAPS, AND OTHER METAL PARTS OF THE VEHICLE.
NHTSA complaint #11378030 — an unverified report by a vehicle owner.
TL* THE CONTACT OWNS A 2007 TOYOTA FJ CRUISER. THE CONTACT STATED THAT THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC FOR TIRE REPAIRS AND THE MECHANIC FOUND THAT THE FUEL TANK STRAPS WERE SEVERELY CORRODED AND THE SUBFRAME WAS ALSO SEVERELY CORRODED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS CONTACTED AND INFORMED OF THE FAILURE. THE FAILURE MILEAGE WAS 71,000.*DT THE CONSUMER PROVIDED PHOTOS.
NHTSA complaint #11375059 — an unverified report by a vehicle owner.
MY 2007 FJ CRUISER HAS MAJOR PROBLEMS WITH RUST. THIS INCLUDES BEING INFORMED TODAY THAT THE FRAME HAS HOLES THAT HAVE RUSTED THROUGH AND THE VEHICLE WOULD NOT PASS INSPECTION. I HAVE ALREADY PUT A LOT OF MONEY INTO THE VEHICLE REPLACING RUSTED PARTS INCLUDING REPLACING THE FUEL TANK STRAPS LAST YEAR, PARTS OF THE SUSPENSION AND RADIATOR. THIS SEEMS EXCESSIVE DAMAGE DUE TO RUST AND CREATES AN UNSAFE TOYOTA PRODUCT.
NHTSA complaint #11366125 — an unverified report by a vehicle owner.
I HAVE BEEN HAVING NOTHING, BUT PROBLEMS WITH KEEPING MY FJ ALIVE. IT WON'T EVEN KEEP A HOLD LONGER THAN A FEW HOURS. I HAVE ALSO HAD PROBLEMS WITH THE FUEL TANK AS I CAN NEVER GO LOWER THAN 1/4 OF A TANK BECAUSE IT WILL DIE. I HAVE READ THAT OTHER FJS HAVE HAD THEIR FUEL PUMPS REPLACED UNDER RECALL AND I WOULD LIKE MINE DONE AS WELL.
NHTSA complaint #11363755 — an unverified report by a vehicle owner.