1996 Toyota 4Runner Body & structure Problems

FRAME IS RUSTING VARY BADLY, IN TWO YEARS THE FRAME THAT IS THE DRIVE TRAIN WILL BE ALL GONE RUST! AND AUTO WILL NOT BE DRIVABLE THEN

NHTSA ID

11161127

Incident

May 19, 2010

Mileage

200,000 mi

EXCESSIVE FRAME CORROSION. VEHICLE UNSAFE TO DRIVE.

NHTSA ID

11140708

Incident

Jan 1, 2012

MY 1996 TOYOTA 4RUNNER SUFFERS FROM EXCESSIVE RUST THAT CAUSED ME TO BE HAVE A HORRIBLE LOSS OF VEHICLE CONTROL DUE TO THE FRAME EXCESSIVELY CRACKING. THE CRACKING WAS DUE TO WHAT AN INDEPENDENT RESEARCH COMPANY STATING THAT THE RIGHT-REAR FRAME RAIL CRACKED AND SEPARATED FROM THE FRAME DUE TO EXCESSIVE RUSTING. THE INDEPENDENT RESEARCH COMPANY POINTED TO NUMEROUS KNOWN REPORTING'S ON THE INTERNET AS A COMMON OCCURRENCE OF THIS VEHICLE. I MADE A PERSONAL CALL TO TOYOTA CUSTOMER CARE AND WAS TOLD THAT THEY LOGGED MY COMPLAINT BUT THAT THEY WOULD NOT COVER ANY CLAIMS HEREIN TO HELP IN FIXING THE ISSUE. MY VEHICLE ONLY HAD APPROXIMATELY 137,000 MILES AT THE TIME OF THE INCIDENCE. THE OCCURRENCE HAPPENED WHEN I WAS TRAVELING ON AN INTERSTATE AT APPROXIMATELY 65 MILES PER HOUR. I CROSSED AN AREA THAT HAD STANDING WATER (NOT DEEP BY ANY MEANS MIND YOU) AND THE REAR END COMPLETELY SHIFTED OUT TO THE RIGHT OF ME AND CAUSED ME TO SPIN. THIS WATER WENT ACROSS ALL THREE LANES AND NO ONE ELSE EXPERIENCED ANYTHING LIKE I DID. THE VEHICLE COMPLETELY SPUN AROUND AND I ENDED UP IN THE EMERGENCY LANE FACING HEAD ON AT ONCOMING TRAFFIC. I WAS FORTUNATE THAT NO ONE WAS INJURED OR HIT IN THE INCIDENT. HOWEVER, THE VEHICLE WAS NOT SAFE TO DRIVE DUE TO THE SEPARATION FROM THE FRAME AFTER THIS. I AM UPLOADING THE RESULTS OF THE INDEPENDENT ASSESSMENT STATING THEIR FINDINGS AND SHOWING PICTURES OF WHAT HAS HAPPENED.

NHTSA ID

11122229

Incident

May 15, 2018

Mileage

137,000 mi

FRAME RUST, A FAIR AMOUNT OF RUST IS CAUSING CONCERN AND MAKES ME QUESTION HOW TRUSTWORTHY VEHICLE IS. THE DATE LISTED ISNT THE DATE OF THE INCIDENT ITS ROUGHLY AROUND THE TIME THE EXTENT OF THE RUST HAD BEEN NOTICED.

NHTSA ID

11113716

Incident

Apr 2, 2018

Mileage

302,182 mi

FRAME IS RUSTING FROM INSIDE OUT. HOLES IN FRAME BIG ENOUGH TO PUSH YOUR WHOLE ARM THROUGH. AREAS OF FRAME CONNECTED TO SUSPENSION PREMATURELY RUSTING OUT. THIS REST OF THIS VEHICLE IS IN EXCELLENT CONDITION, BODY PANELS INCLUDED. WELDER TOLD ME ENTIRE FRAME IS RUSTING AWAY AND REPAIR TO THE FRAME IS VERY DIFFICULT ANF EXPENSIVE EVEN IF POSSIBLE. VEHICLE HAS UNDER 185,000 MILES AND RUNS GREAT. I HEAR CREAKING DEVELOPING AND AM AFRAID CAR MAY SPLIT IN HALF. WHY IS TOYOTA NOT STEPPING UP AFTER ADMITTING TO BADLY MANUFACTURED FRAMES.

NHTSA ID

11082258

Incident

Jan 3, 2018

Mileage

175,000 mi

THE FRAME HAS PREMATURELY RUSTED THROUGH IN FRONT OF THE RIGHT, REAR TRAILING ARM. MY SHOP TELLS ME THE FRAME IS TOO RUSTED TO REPAIR IT.

NHTSA ID

11015853

Incident

Aug 16, 2017

Mileage

175,000 mi

TAKATA RECALL I'M SUPER DISAPPOINTED IN THE RUST PROBLEM WITH TOYOTAS, I'VE OWNED NOW THREE TACOMAS, ALL RUSTED OUT, I RECENTLY GAVE UP AND TRIED BUYING A 1996 4RUNNER, GOT A REALLY GOOD DEAL ON IT, I CAN SEE WHY ANYWAYS I BOUGHT IT AND IT TURNS OUT THE WHOLE FRAME WAS COATED SO I COULDN'T SEE RUST, WITH FURTHER INSPECTION THERE'S A BIG CRACK IN THE FRAME FROM RUST, AND THE WHOLE FRAME IS RUSTED. THE CRACK IS RIGHT BESIDE THE EXHAUST, I CONTACTED TOYOTA AND THEY SAID BRING IT IN FOR INSPECTION AND THEY SAID IT WOULD NEED REPLACED, BUT WOULD COST 14-16 THOUSAND DOLLARS. THEN THEY CHARGED ME FOR THE INSPECTION 60 DOLLARS, WHEN THEY DIDN'T EVEN TELL ME I'D BE CHARGED. TOYOTA REALLY NEEDS TO STEP UP!!! FEEL FREE TO CALL ME AT [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6). *TR

NHTSA ID

11015313

Incident

Aug 8, 2017

WHILE CORNERING IN CITY DRIVING I HEARD A CLUNKING NOISE AND INVESTIGATED WHEN I ARRIVED HOME. THE FRAME HAS CORROSION AT THE RIGHT REAR TRAILING ARM BRACKET. THE BRACKET WAS RUSTED AWAY FROM THE FRAME AT THE TOP BUT STILL ATTACHED AT THE BOTTOM. THE BRACKET AND FRAME WERE WELDED WITH ADDTIONAL METAL. I CHECKED THE REST OF THE FRAME AND NOTICED THERE IS ALSO A HOLE IN THE CROSSMEMBER BELOW THE DRIVERS SEAT AND OTHER LARGER RUSTED HOLES ALONG THE FRAME. THIS IS A MAJOR SAFETY CONCERN. I WILL HAVE TO TAKE IT TO A FRAME SHOP AS TOYOTA SAYS THERE IS NO RECALL ON THE 4RUNNER ONLY THE TACOMA AND TUNDRA. I KNOW MANY OTHER 3RD GENERATION 4RUNNER OWNERS WHO HAVE THE SAME PROBLEM. THE VEHICLE BODY HAS NO RUST OTHER THAN A SMALL SURFACE AREA AT THE DRIVERS DOOR ROCKER PANEL AND NEAR THE WINDSHIELD. THE VEHICLE IS VERY WELL MAINTAINED.

NHTSA ID

10993315

Incident

Sep 6, 2016

Mileage

248,000 mi

I OWN A 1996 TOYOTA 4RUNNER THAT HAS FRAME IS RUSTED WITH LARGE HOLES. IT HAS NOT CAUSED AN ACCIDENT YET BUT I BELIEVE THE MANUFACTURER SHOULD BE HELD ACCOUNTABLE. ESPECIALLY WHEN THE SAME COMPANY HAS REPLACED FRAMES AND BOUGHT BACK OTHER MODELS FOR THE EXACT SAME ISSUE. HOW AM I (AS A 4RUNNER OWNER) JUST OVERLOOKED AND BRUSHED ASIDE.

NHTSA ID

10938869

Incident

Jun 20, 2016

Mileage

180,000 mi

TRAVELING NB APPROACHING GREEN LIGHT AND A CAR RAN RED LIGHT IN INTERSECTION. THE CAR ON SB SWERVED ON MISS THEM, HIT THEM ANYWAY AND HIT ME HEAD ON. BOTH ON THEIR AIR BAGS WENT OFF AND MINE DID NOT. I AM STILL IN PHYSICAL THERAPY FOR PARTIAL ROTATOR CUFF TEAR, SPRAINED NECK, BACK, SHOULDER, ELBOW AND I STILL CANNOT USE RIGHT ARM FROM ELBOW DOWN. I HAVE NOT WORKED SINCE THE ACCIDENT. I WANT TO KNOW WHY MY AIR BAGS DID NOT GO OFF.

NHTSA ID

10904932

Incident

Jun 13, 2016

Mileage

255,500 mi

SECOND OWNER OF THIS SUV THAT I HAVE OWNED FOR 12 YEARS. FRAME RUST ISSUES HAVE PROCEEDED TO THE POINT WHERE ONE MONTH AGO, THE LEFT REAR LATERAL AXLE LINK BRACKET BROKE FREE FROM THE FRAME. THE CAR IS NOW UNSAFE TO DRIVE BECAUSE THE REAR AXLE IS NOT TIED TO THE FRAME ON THE DRIVER'S SIDE. MECHANIC TOLD ME IT MIGHT BE ABLE TO BE FIXED/WELDED, BUT THE REST OF THE FRAME IS SO BAD THERE ISN'T MUCH TO WELD TO. I HAVE FOUND NUMEROUS OTHER COMPLAINTS ONLINE ABOUT THIS GENERATION 4RUNNER AND ITS FRAME RUST ISSUES. I ALSO FOUND MANY CASES WHERE THE EXACT SAME ISSUE WITH THE AXLE LINK BRACKET HAS OCCURRED. THIS REALLY SEEMS TO BE A BROADER ISSUE THAT TOYOTA HAS NOT REMEDIED FOR 4RUNNER OWNERS. DISAPPOINTED THAT I'M NOT ABLE TO KEEP THIS LONGER LIKE I'D PLANNED.

NHTSA ID

10894693

Incident

Jul 1, 2016

Mileage

161,000 mi

1996 TOYOTA 4RUNNER WILL NOT PASS PENNSYLVANIA SAFETY INSPECTION DUE TO FRAME RUST AND DETERIORATION. EXTENT OF DAMAGE MAY INHIBIT REPAIR WITHOUT TOTAL FRAME REPLACEMENT. VEHICLE IS NOT OPERABLE WITHOUT INSPECTION.

NHTSA ID

10871337

Incident

May 25, 2016

Mileage

324,000 mi

I HAVE OWNED MY 4RUNNER FOR 26 YEARS AND I HAVE METICULOUSLY CARED FOR IT. ONE OF MY SHOCKS GAVE WAY AND I BROUGHT IT IN FOR MY TECHNICIAN TO INSPECT IT. UPON MY HIS INSPECTION I WAS NOTIFIED ABOUT THE EXTENSIVE RUST ON THE FRAME AND OTHER PARTS UNDER THE TRUCK SUCH AS THE GAS LINE. I WAS INFORMED THAT MY ENGINE RUNS STRONG WITH 209K ON IT. MY TECHNICIAN WOULD NOT DO ANY REPAIRS TO THIS FRAME BECAUSE OF HOW COORS ICE IT WAS. HE SHOWED ME SEVERAL FINGERS GOING THROUGH A STRESS POINT NEAR THE REAR AXEL. THE TRUCK LOOKS BEAUTIFUL AND IS NOW USELESS WITH THE RUSTY FRAME. I LIVE IN SALTY CT AND BELIEVE THE FRAME WAS NOT PROPERLY CONDITIONED FROM THE FRAME FACTORY. VIN NUMBER: [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6). *TR

NHTSA ID

10862417

Incident

May 1, 2016

FRAME BROKE DUE TO RUST BY THE LOWER CONTROL ARM GOING STRAIGHT DOWN THE ROAD DOING ABOUT 30MPH ALMOST CAUSING ME TO GO OFF THE ROAD. HAD IT TOWED TO A LOCAL GARAGE TO FIND OUT IT WAS RUSTED THROUGH IN SEVERAL PLACES AND THE MECHANIC TOLD ME IT WAS A COMMON PROBLEM WITH THIS YEAR OF 4RUNNER. IF THIS HAD HAPPENED GOING DOWN THE HIGHWAY IT COULD OF COSTED ME MY LIFE OR SOMEONE ELSE'S AND BEING AS COMMON OF A PROBLEM AS IT IS I FEEL IT SHOULD BE ADDRESSED THERE'S NO REASON A FRAME SHOULD RUST AS BAD AND AS QUICK AS THIS CONSIDERING IT HAS BEEN UNDERCOATED EVERY YEAR OF ITS LIFE

NHTSA ID

10821595

Incident

Jan 19, 2016

Mileage

265,000 mi

TL* THE CONTACT OWNS A 1996 TOYOTA 4RUNNER. WHILE DRIVING 40 MPH, THE VEHICLE BEGAN TO WOBBLE UNCONTROLLABLY. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHERE IT WAS DIAGNOSED THAT THE FRAME ON THE DRIVER SIDE HAD COMPLETELY RUSTED AND NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS 224,000.

NHTSA ID

10787949

Incident

Oct 16, 2015

Mileage

224,000 mi

HI, THE FRAME IS EXTREMELY RUSTED. IT HAD A SMALL TEAR ON A WELD. NOW IT HAS A LARGE TEAR IN THE FRAME. IT APPEARS THAT IT IS RUSTING AT ALL THE WELD POINTS AT A ACCELERATED RATE AND OR THE FRAME ITSELF IS NOT THICK ENOUGH. I HAVE READ OF HUNDREDS OF OTHERS THAT OWN THIS CAR AND THE FRAME HAS RUSTED THROUGH. I KNOW THAT THE TACOMA HAS BEEN RECALLED AND IT HAS THE EXACT SAME FRAME-------PLEASE ADVISE AS THIS CAR IS NOT EVEN 20 YEARS OLD......THE CAR IS IN GREAT CONDITION OTHERWISE AND IN NO WAY SHOULD BE READY FOR THE JUNK YARD........

NHTSA ID

10760591

Incident

Aug 25, 2014

Mileage

200 mi

I RECENTLY BOUGHT MY 1996 4RUNNER AT THE BEGINNING OF 2015. THERE WAS SOME RUST ON THE FRAME BUT NO NOTICEABLE DAMAGE FROM THE OUTSIDE. NOW, SIX MONTHS LATER I HAD IT LOOKED AT BECAUSE THE EXHAUST SYSTEM BECAME INCREASINGLY LOUD. THE MECHANIC LOOKED AT THE FRAME WHILE LOOKING AT THE EXHAUST SYSTEM AND HE FOUND THAT THE FRAME HAD ROTTED FROM THE INSIDE OUT. HE RECOMMENDED I DO NOT DRIVE IT ANYMORE AS IT IS UNSAFE. HE SAID HE WOULD NEVER ATTEMPT TO REPAIR DAMAGE SUCH AS MY 4RUNNER HAS. MY VEHICLE ONLY HAS 166,000 MILES ON IT. THERE IS NO REASON THE FRAME SHOULD BE AS DAMAGED AS IT IS OR TO HAVE IT RUSTED FROM THE INSIDE OUT.

NHTSA ID

10735007

Incident

Jul 10, 2015

Mileage

165,000 mi

I HAVE EXTREME FRAME RUST.

NHTSA ID

10717222

Incident

May 18, 2015

MY SON WAS DRIVING VEHICLE AND HIT A POTHOLE CAUSING DAMAGE TO THE VEHICLE. AFTER FURTHER INSPECTION THE FRAME HAD BROKE INTO BECAUSE IT WAS RUSTING FROM THE INSIDE OUT. *TR

NHTSA ID

10694406

Incident

Mar 10, 2015

Mileage

246,000 mi

I WAS DRIVING DOWN THE HIGHWAY WITH MY SON IN THE CAR WHEN I HEARD A LOUD NOISE COMING FROM THE PASSENGER SIDE OF THE TRUCK AND IMMEDIATELY FOLLOWED WITH A LOSS OF CONTROL. LUCKILY IT WAS IN THE AFTERNOON AND RUSH HOUR HAD YET TO HIT SO THE NEAREST CARS/TRUCKS WERE ABLE TO AVOID ME. I LIMPED TO THE SIDE OF THE HIGHWAY AND LOOKED UNDER THE TRUCK ONLY TO SEE THAT THE FRAME RAIL ON THE PASSENGER SIDE HAD COMPLETELY SNAPPED IN HALF. UPON FURTHER INSPECTION IT HAD CLEARLY RUSTED FROM THE INSIDE OUT. I HAVE KEPT THE TRUCK IN EXCELLENT SHAPE, REGULAR MAINTENANCE, ETC AND EVEN CHECKED FOR RUST SINCE I KNEW THIS WAS AN ISSUE. HOWEVER SINCE IT RUSTED FROM THE INSIDE OUT, I HAD NEVER EVEN NOTICED. GOT IT TOWED TO THE DEALER WHO WOULD PROCEED TO INFORM ME THAT THE ONLY FIX FOR IT WAS A NEW FRAME. PERFECT 4RUNNER, LOW MILES, WITH EXCELLENT CARE TAKEN TO MAKE SURE IT WOULD LAST 300K, AND NOW ITS WORTH LESS THAN A ROTTEN BANANA. TALK ABOUT A PUNCH TO THE FACE. IM JUST THANKFUL MY FAMILY AND I WERE NOT HURT IN THIS MESS. I'VE READ ABOUT THE CONSTANT RUST ISSUES WITH THESE TRUCKS AND I PRAY THAT IT DOESN'T HURT AN ENTIRE FAMILY SOMEWHERE IN THE FUTURE OTHER THAN THEIR WALLET. *TR

NHTSA ID

10682784

Incident

Feb 5, 2015

Mileage

137,200 mi

TL* THE CONTACT OWNS A 1996 TOYOTA 4RUNNER. THE CONTACT STATED WHILE DRIVING APPROXIMATELY 45 MPH, AN ABNORMAL NOISE EMITTED FROM THE REAR PASSENGER SIDE OF THE VEHICLE. THE CONTACT DISCOVERED THAT THE FRAME WAS RUSTED AND DETACHED OFF THE VEHICLE. THE VEHICLE WAS TAKEN TO THE DEALER. THE TECHNICIAN DIAGNOSED THAT THE FRAME NEEDED TO BE REPLACED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS 260,000. THE VIN WAS UNAVAILABLE.

NHTSA ID

10648382

Incident

Oct 16, 2014

Mileage

260,000 mi

THE FRAME ON MY 1996 4RUNNER IS RUSTED BEYOND REPAIR. A PLACE WITH SIGNIFICANT RUST HAD BEND AND WOULD BREAK OFF AT ANY MOMENT. THE VEHICLE IS UNSAFE TO DRIVE AND COMPLETELY USELESS AT THIS POINT. *TR

NHTSA ID

10641362

Incident

Oct 2, 2014

Mileage

179,300 mi

WHILE DRIVE DOWN THE HIGH WAY AT ABOUT 65 MPH I WAS DRIVING AND ALL OF A SUDDEN I HEARD A LOUD CLUNK UNDER MY TRUCK. I DIDN'T HIT ANYTHING IN THE ROAD I JUST HEARD A LOUD CLUNK AND AFTER THAT MY TRUCK WOULD SWAY AND DRIFT TO THE LEFT DRAMATICALLY TO THE POINT I ALMOST COULDN'T CONTROL WHAT DIRECTION MY TRUCK WAS GOING I HAD TO SLOW DOWN TO 20 MPH AND PULL OVER. AFTER TAKING IT IN TO THE MECHANIC THEY TOLD ME THAT FRAME AS COMPLETELY RUSTED THROUGH AND SNAPPED ENTIRELY. THE TRUCK IS AMAZING TRUCK ENGINE RUNS LIKE ITS BRAND NEW BUT THE ENTIRE FRAME RUSTS WAY TO EASY. AND SOMETHING NEEDS TO BE DONE ON THE 96-99 4RUNNER FRAME. BEFORE SOME ONE GETS IN A ACCIDENT. OR IS THAT WHAT TOYOTAS WAITING FOR BEFORE THEY DO ANYTHING ABOUT THIS MAJOR ISSUE THAT HAPPENS TO ALL 3RD GENERATION 4RUNNER. *TR

NHTSA ID

10618945

Incident

Jul 28, 2014

Mileage

250,000 mi

RUST ON FRAME. ADVISED THAT IT MAY NOT BE SAFE. *TR

NHTSA ID

10597521

Incident

May 15, 2014

Mileage

205,000 mi

TL* THE CONTACT OWNS A 1996 TOYOTA 4RUNNER. THE CONTACT STATED THAT THE FRAME WAS DAMAGED TO THE POINT OF DETERIORATION. THE AFFECTED AREA WAS NEAR THE REAR PASSENGER SIDE IN FRONT OF THE REAR WHEEL. THE CONTACT TOOK THE VEHICLE FOR A ROUTINE INSPECTION BY AN INDEPENDENT MECHANIC WHO DIAGNOSED THAT THE FRAME NEEDED TO BE REPLACED. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER WHO OFFERED AN INTERIM FIX TO COAT THE EXTENSIVE RUSTING AND THE DETERIORATION OF THE FRAME. THE AUTHORIZED DEALER DID NOT PROVIDE THE REMEDY TO REPLACE THE FRAME. THE VEHICLE WAS SCHEDULED TO BE REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE SEVERAL TIMES TO NO AVAIL. THE APPROXIMATE FAILURE MILEAGE WAS UNKNOWN.

NHTSA ID

10596107

Incident

May 2, 2014