2002 Toyota 4Runner Powertrain (other) Problems

The contact owns a 2002 Toyota 4Runner. The contact stated that while driving, the vehicle lost power while depressing the accelerator pedal. The failure initially occurred without warning; however, the VSC (Vehicle Stability Control) message was displayed with an audible beeping sound coming from the vehicle. In addition, there was a red warning light flashing on the instrument panel after the failure. The contact stated that the failure occurred mostly while turning the steering wheel to the left or the right. The manufacturer was notified of the failure and referred the contact to the dealer and the NHTSA Hotline for assistance. The failure mileage was approximately 200,000.

NHTSA ID

11769948

Incident

Apr 1, 2026

Mileage

200,000 mi

WHEN THE CHECK ENGINE LIGHT IS ILLUMINATED, THE TRACTION CONTROL AND ANTI LOCK BRAKE FEATURES ARE AUTOMATICALLY DISABLED.

NHTSA ID

11229403

Incident

Jul 2, 2019

I PURCHASED THE 2002 4RUNNER IN 2014. AT THAT TIME, THE 4RUNNER ONLY HAD 79,000 MILES AND HAD BEEN CARED FOR METICULOUSLY. I HAVE TAKEN THE CAR IN FOR ROUTINE SERVICE OVER THE PAST 5 YEARS. UPON TAKING THE 4RUNNER IN DUE TO A VIBRATION AND CHECK OF THE DIFFERENTIAL, THE MECHANIC CALLED ME IN TO LOOK AT THE FRAME WHILE IT WAS UP ON THE LIFT. BELOW IN THE ATTACHED PHOTOS, THERE IS EXTENSIVE RUSTING OF THE REAR DIFFERENTIAL, AXLE AND FRAME. THE VEHICLE WAS STATIONARY AND THE ISSUE WAS FOUND DURING ROUTINE MAINTENANCE. THE RUSTED FRAME AND DIFFERENTIAL HAVE RENDERED THIS VEHICLE PRACTICALLY VALUELESS AND UNSAFE.

NHTSA ID

11217310

Incident

May 24, 2019

Mileage

128,000 mi

"TAKATA RECALL" FRAME RUSTED OUT FROM THE INSIDE OUT. LOOKING AT ON FRAME IT WAS AT LEAST 1.5 INCHES OF DIRT AND SMALL ROCK FROM MAINE ROADS AND THAN WHEN RAINED IT WAS JUST MUD THE BAD SPOT IS ON THE PASSENGER SIDE D BY TORSION BAR NO WAY TO DRAIN. ALSO REAR END DIFFERENTIAL GEAR COVER RUSTED OUT ON OTHER VEHICLES YOU REPLACED JUST THE COVER ON THE 4RUNNER I WAS TOLD TO REPLACE THE REAR END PRICE JUST FOR THE REAR END WAS $2500 THAN LABOR.

NHTSA ID

11035790

Incident

Oct 23, 2017

Mileage

191,000 mi

REAR DIFFERENTIAL COVERED RUSTING THROUGH.

NHTSA ID

10956666

Incident

Jan 1, 2016

REAR DIFFERENTIAL RUSTED THROUGH

NHTSA ID

10852495

Incident

Mar 1, 2016

Mileage

172,568 mi

I TOOK MY VEHICLE IN FOR A ROUTINE OIL CHANGE RECENTLY AND THE TECHNICIAN SAID THAT I HAVE SOME MAJOR RUST ISSUES ON MY REAR AXLE AND DRIVETRAIN. HE SHOULD ME WHEN IT WAS ON THE LIFT. HE EXPLAINED TO ME THAT THE BOLT AND CLIP THAN HOLDS THE BRAKE LINE DOWN ON THE REAR DIFFERENTIAL HAD RUSTED AND BROKEN OFF OF THE DIFFERENTIAL COVER. THE REAR DIFFERENTIAL IS NOW LEAKING GEAR OIL. THE TECHNICIAN ADVISED ME THAT IT IS TOO RISKY TO ATTEMPT TO REPAIR AS IT MAY CAUSE THE ENTIRE DIFFERENTIAL TO BE DAMAGED AND THE WHOLE REAR AXLE WOULD NEED TO BE REPLACED. THE TECHNICIAN ALSO SAID THAT IT IS A RISK TO DRIVE THE VEHICLE AND IS POSSIBLY UNSAFE TO KEEP DRIVING. HE STATED THAT IT IS UNKNOWN HOW MUCH LONGER I WOULD BE ABLE TO DRIVE IT UNTIL THE REAR AXLE CEASES.

NHTSA ID

10826027

Incident

Dec 14, 2015

Mileage

138,000 mi

MY FRAME IS ROTTING OUT. I JUST HAD TO REPLACE MY REAR AXLE BECAUSE IT HAD ALMOST ROTTED THROUGH. IT WAS ACTUALLY WEAPING GEAR OIL OUT OF SMALL HOLES THROUGH THE ROT. SOME OF THE FRAME HAD TO BE WELDED TO PASS INSPECTION.

NHTSA ID

10777896

Incident

Sep 27, 2015

Mileage

136,000 mi

THE FRAME IS RUSTING ALMOST IN TWO. LOOKS LIKE IT COULD BREAK ANY TIME. REAR AXEL IS ALSO VERY RUSTED WITH PIECES FALLING OFF. *TR

NHTSA ID

10701395

Incident

Mar 24, 2015

Mileage

60,000 mi

FRAME AND REAR DIFFERENTIAL RUSTING OUT. *TR

NHTSA ID

10666960

Incident

Dec 17, 2014

Mileage

158,000 mi

TL* THE CONTACT OWNS A 2002 TOYOTA 4RUNNER. THE CONTACT STATED THAT FLUID WAS LEAKING UNDER THE VEHICLE. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC. THE TECHNICIAN DIAGNOSED THAT THE REAR DIFFERENTIAL HOUSING WAS RUSTED, LEAKED FLUID INTERMITTENTLY AND THERE WERE MULTIPLE HOLES TO THE POINT THAT THE COMPONENT MAY FRACTURE. THE REAR DIFFERENTIAL NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS NOT AVAILABLE.

NHTSA ID

10661047

Incident

Nov 12, 2014

REAR DIFFERENTIAL HAS RUSTED THROUGH, THE WHOLE THING HAS TO BE REPLACED BECAUSE THERE IS NO SEPARATE COVER THE REPAIR COST MAY BE HIGH. *TR

NHTSA ID

10653785

Incident

Nov 3, 2014

Mileage

112,000 mi

4 WHEEL DRIVE WOULD NOT WORK. VCS LITES AND CHECK ENGINE LITES ON. CAR ENGINE FILLED WITH BLACK SMOKE AND WAS TOWED TO REPAIR SHOP. DETAILS: DROVE ON FREEWAY AND LOST TRACTION AND THAN ON SHOULDER WITH ABOVE PROBLEM. DIFFERENTIAL REPAIRED. TWO DAYS LATER LITES ON AGAIN AND OIL LEAK. *TR

NHTSA ID

10629903

Incident

Aug 28, 2014

Mileage

142,986 mi

I FILED A NHTSA COMPLAINT (ODI NUMBER 10569206 WAS ASSIGNED) ON 13 MARCH 2014 ABOUT THIS VEHICLE. ON 14 MARCH 2014, I TOOK MY 4RUNNER TO MY LOCAL TOYOTA DEALERSHIP AFTER CONTACTING TOYOTA CUSTOMER SERVICE AND LOGGING A COMPLAINT ( CASE NUMBER [XXX] ) WITH THEM ON THE 14TH OF MARCH 2014 AT THEIR OFFICE IN CALIFORNIA AND THE CUSTOMER SERVICE REP TELLING ME DOCUMENTATION OF THE ISSUE AT MY DEALERSHIP WOULD HELP ME. THIS VEHICLE WAS BOUGHT IN NY AND REMAINED UP NORTH FOR 10 YEARS AND ACCORDING TO EMERSON TOYOTA AUBURN, ME RECORDS AT 85,199 MILES ON 07/11/2012. SERVICE ADVISER, [XXX] CONDITION1 AT 85,199 MILES . USED CAR PREP. VEHICLE BEING WHOLESALED PER RICH. NEEDS ENGINE LIGHT ON, A/C INOP, REAR AXLE HOUSING VERY RUSTED AND CRACKED, HOOD LATCH INOP, RADIATOR LEAKING, FRAME IS SOFT. IT HAD 85,404 MILES WHEN IT CAME TO FLORIDA ON 07 SEPTEMBER 2012 MY 2002 TOYOTA 4RUNNER SR5 WITH ONLY 112109 MILES AT COGGIN TOYOTA AT THE AVENUES DEALERSHIP ON PHILIPS HWY IN JACKSONVILLE, FLORIDA AT 12:20PM ON 14 MARCH 2014 MY COMPLAINT AT THE DEALERSHIP ON 14 MARCH 20014 AT 12:20.........CUSTOMER STATES REAR SUBFRAME IS RUSTED. CHECK AND ADVISE. THEIR FINDINGS AT 12:55PM ON 14 MARCH 2014... CASE NUMBER [XXX], FOUND SEVERE FRAME RUST, HOLES IN FRAME ON RIGHT SIDE, HOLES RUSTED THROUGH FRAME BY GAS TANK ON LEFT SIDE.HOLES RUSTED THROUGH GAS TANK AND LEAKING FUEL. UPPER REAR TRACK BAR BRACKET RUSTED OFF OF REAR END HOUSING, REAR SHOCKS RUSTED OFF. FRONT BRAKE ROTOR BACKING PLATES RUSTED THROUGH. THE VEHICLE IS UNSAFE TO DRIVE DUE TO FUEL LEAK AND EXTREME RUST THROUGH OF FRAME. I WANT THIS VEHICLE FRAME AND AXLE FIXED OR BOUGHT BACK BY TOYOTA. A TOYOTA DEALERSHIP IN AUBURN, ME KNEW OF THIS PROBLEM ALMOST 2 YEARS AGO AND SENT IT OUT THE DOOR. TOTALLY UNSATISFACTORY. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6). *TR

NHTSA ID

10572597

Incident

Mar 13, 2014

Mileage

112,109 mi

VEHICLE FRAME, FRONT & REAR BUMPERS AND UNDERCARRIAGE HAVE EXCESSIVE / UNSAFE RUST CORROSION. *TR

NHTSA ID

10559158

Incident

Jan 3, 2011

Mileage

138,000 mi

REAR AXLE ASSEMBLY ROT! NOW LEAKING ON REAR NON REPLACEABLE YOKE COVER. 1800-2000 DOLLAR FIX. TO MAKE THINGS WORSE AXLE ASSEMBLY HAS NO TAGS!!!! TOLD BY DEALER DOOR TAGS ARE OFTEN WRONG SO ORDERING RECYCLED (IF YOU CAN FIND ONE IN BETTER SHAPE) IS A GAMBLE!!!! HAS BEEN A DEPENDABLE TRUCK OTHER WISE BUT NOW IT SEEMS AS THOUGH THEY ARE PROFITING FROM THERE DESIGN FLAWS. *TR

NHTSA ID

10556662

Incident

Nov 1, 2013

Mileage

190,000 mi

(THERE WAS NO CATEGORY OFFERED FOR FRAME). DURING A RECENT AUTOMOTIVE SERVICE FOR BRAKES ON 9-26-13 FOR MY 2002 TOYOTA 4RUNNER, I WAS NOTIFIED OF A RUST PERFORATION IN THE FRAME BODY NEAR A REAR SUPPORT MOUNT FOR THE AXLE MAKING IT UNSAFE FOR OPERATION. THIS IS A SITUATION WHERE RUST FORMS IN THE INTERIOR OF THE FRAME AND WORKS ITS WAY OUT DESTROYING THE STRUCTURAL INTEGRITY OF THE VEHICLE. IT SEEMS THE SERVICE TECHNICIAN USED TO WORK AT A TOYOTA DEALERSHIP AND KNEW EXACTLY WHERE TO LOOK FROM HIS PRIOR EXPERIENCE WITH OTHER 4RUNNER FAILURES. THE TOYOTA DEALER INFORMED THAT THIS WOULD NOT BE COVERED. MY ?02 4RUNNER IS FROM THE SAME GENERATION (3RD) AND OF SIMILAR DESIGN TO THE TACOMA THAT WAS RECALLED FOR THIS THE DEALER INSTRUCTED ME TO CONTACT THE TORRANCE, CA TOYOTA CUSTOMER SERVICE AS HIS DEALERSHIP WOULD BE UNABLE TO ASSIST IN ANYWAY. IT WAS CLEAR THEY HAD ENCOUNTERED THIS BEFORE. THROUGH DISCUSSION WITH TOYOTA CA THEY HAVE NO INTENTION OF PROVIDING ANY MEANS OF RELIEF FOR A KNOWN AND WELL DOCUMENTED SAFETY PROBLEM. ONE REP DID COMMENT THAT THE TUNDRA AND SEQUOIA HAD BEEN RECENTLY ADDED TO THE RECALL BUT THE 4RUNNER WAS ?NOT YET? ON THE RECALL LIST. IT SEEMS TOYOTA VIEWS THE PRODUCTS TO BE DIFFERENT DUE TO THE BODY STYLE DIFFERENCES OR US VS JAPANESE BUILT PRODUCTS. THEY ALSO CLEARLY HAVE NO INTENTION TO ESCALATE INTERNALLY. I WAS INSTRUCTED TO FILE A COMPLAINT WITH NHTSA AND NTSB. RESEARCH ON LINE SHOWS THAT THERE IS A VERY WIDESPREAD ISSUE THAT TOYOTA IS CLEARLY CHOOSING TO IGNORE. WEB INFORMATION SUGGESTS THAT COLD CLIMATE AND THE AXLE BRACKET IN CLOSE PROXIMITY TO THE EXHAUST, ARE PRIMARY FACTORS. HOW CAN YOU RECALL ONE MODEL FOR A RUSTED FRAME DUE TO SAFETY BUT NOT ANOTHER? PERSONAL PHOTOS AVAILABLE. HUGE NUMBERS OF PHOTOS AND REPORTS AVAILABLE ONLINE - SEARCH " RUSTED FRAME 4RUNNER" OR SIMILAR. *TR

NHTSA ID

10546324

Incident

Sep 26, 2013

Mileage

113,000 mi

2002 TOYOTA 4 RUNNER. CONSUMER WRITES IN REGARDS TO VEHICLE GAS PEDAL MALFUNCTION. *SMD THE CONSUMER STATED AFTER STOPPING AT A STOP SIGN, HE ATTEMPTED TO MOVE FORWARD, BUT THE VEHICLE WOULD NOT MOVE. AFTER SEVERAL TRIPS TO THE DEALER, THE PROBLEM WAS FIXED. HOWEVER, THE CONSUMER DID STATE WHAT THE PROBLEM WAS.

NHTSA ID

10537659

Incident

Feb 1, 2013

THE DIFFERENTIAL HOUSING IS RUSTING OUT AND IS SEEPING FLUID. IN ADDITION, THE FRAME IS DANGEROUSLY RUSTED, ESPECIALLY FROM THE REAR AXLE BACK. I HAVE BEEN TOLD BY A VERY REPUTABLE BODY SHOP IN THE AREA, THAT THE FRAME NEEDS TO BE REPLACED, BUT DUE TO THE SEVERITY OF THE RUST, THIS IS NOT PRACTICAL. TOYOTA IS REPLACING FRAMES ON THEIR TUNDRA PICKUPS DUE TO RUST, BUT REFUSES TO COVER 4RUNNERS, THOUGH THEY SHARE THE SAME FRAME. IF I DID NOT HAVE THE VEHICLE SERVICED BY THE DEALER REGULARLY, I WOULD BE UNAWARE OF THE DANGEROUS CONDITION OF THE FRAME. *TR

NHTSA ID

10515964

Incident

May 17, 2013

Mileage

132,000 mi

RECENTLY PURCHASED THIS VEHICLE AND STARTED CLEANING IT, AFTER I DROVE IT HOME AND PRESSURE WASHED UNDERCARRIAGE, PIECES OF THE REAR DIFFERENTIAL STARTED FLYING OFF AND GEAR OIL STARTED RUNNING OUT OF HOLES. I HAVE A 1971 DODGE CHALLENGER WITH ORIGINAL REAR END THAT HAS NEVER BEEN IN GARAGE AND HAVE NEVER SEEN A REAREND RUST LIKE THIS. I'M REALLY WORRIED ABOUT HOW STRONG THE AXLE HOUSING STRUCTURE IS AND IF IT COULD POSSIBLE BREAK IN HALF WHILE DRIVING VEHICLE. *TR

NHTSA ID

10513553

Incident

May 20, 2013

Mileage

132,000 mi

MY 4RUNNER HAS 72000 MILES ON IT, AND I JUST REALIZED THE REAR DIFFERENTIAL HOUSING HAS RUSTED THROUGH. THE METAL IS SO THIN THAT THE FLUID IS LEAKING OUT THROUGH THE POURS OF THE METAL. I TOOK IT TO THE DEALER AND THEY SAID IT WOULD COST 3000$+ TO REPLACE THE ENTIRE REAR END. THERE IS NO OTHER RUST UNDER THE VEHICLE EXCEPT FOR THE PUMPKIN HOUSING. AFTER LOOKING AROUND ON THE INTERNET I FOUND THIS IS A COMMON PROBLEM, OF THE HOUSING NOT ONLY BEING TOO THIN OF METAL FOR THE APPLICATION, BUT LOW QUALITY STEEL THAT'S PRONE TO CORROSION. *TR

NHTSA ID

10481316

Incident

Oct 17, 2012

Mileage

72,000 mi

AFTER NOTICING A STRONG GEAR OIL ODOR AND SEEING THE ACTUAL GEAR OIL ON THE BACK THE OF THE VEHICLE I WAS ALARMED TO FIND OUT THAT THE REAR AXLE HOUSING HAD RUST PERFORATING THE REAR OF THE HOUSING. ONCE THE HOUSING WAS CHECKED BY A CERTIFIED MECHANIC AND TURNED AWAY DUE TO FEAR OF DESTROYING THE HOUSING, I REMOVED THE VEHICLE FROM THE ROAD. *TR

NHTSA ID

10474018

Incident

Aug 6, 2012

Mileage

203,000 mi

REAR DIFFERENTIAL RUST THROUGH. *TR

NHTSA ID

10454833

Incident

Apr 4, 2012

Mileage

44,700 mi

2002 4RUNNER SR5 4WD, 141K MILES, COMPLETELY RUSTED THROUGH REAR DIFFERENTIAL, BOTH REAR AXLE SEALS BUSTED OUT, DIFFERENTIAL HOUSING HAS SEVERAL PIN HOLE LEAKS AND IS THINNED OUT, THE ONLY FIX IS A COMPLETELY NEW REAR END, WHICH IS VERY COSTLY, I AM THE 2ND OWNER, I'VE OWNED A 99 4RUNNER THAT HAD THESE SAME REAR DIFFERENTIAL RUST ISSUES, THE RUST IS RIDICULOUS AND HAS DETERIORATED THE WHOLE UNDERCARRIAGE AND MY 4RUNNER IS GARAGE KEPT AND I WASH IT ALL THE TIME. I CAN'T BELIEVE TOYOTA HAS NOT BEEN HELD ACCOUNTABLE FOR THE RUSTING OUT OF REAR DIFFERENTIALS AND REAR AXLE ISSUES. *TR

NHTSA ID

10411676

Incident

Jul 8, 2011

Mileage

141,000 mi

THE REAR DIFFERENTIAL HOUSING HAS RUSTED THROUGH CAUSING ITS OIL TO LEAK OUT. *TR

NHTSA ID

10410344

Incident

Jun 15, 2011

Mileage

158,000 mi