2002 Toyota 4Runner Suspension Problems

The contact owns a 2002 Toyota 4Runner. The contact stated that while driving 60 MPH through a slight right curve, the vehicle independently shifted from side to side without warning nearly causing the vehicle to flip. The contact had an independent mechanic inspect the vehicle and the mechanic discovered severe corrosion throughout the entire subframe of the vehicle. The mechanic informed him that the entire subframe needed to be replaced to ensure safe driving. Neither the dealer nor the manufacturer had been notified of the failure. The vehicle had yet to be repaired. The failure mileage was approximately 115,000.

NHTSA ID

11461138

Incident

Mar 18, 2022

Mileage

115,000 mi

Frame and rear passenger control arm bracket, rotted out .only there, 2 nd time this has happened, same spot but on my previous 2001 4runner

NHTSA ID

11443916

Incident

Apr 17, 2021

Had vehicle inspected on Oct. 1 ,2021 for road trip to North Carolina from Washington, DC. Was informed that my vehicle is unsafe by the automotive shop (name withheld) due to [rusting] frame front suspension components' threads rusted off on bolts that hold suspension, control arms, and shocks on both front and rear areas + body of vehicle located where shocks bolt to the body. I also had two other shops (names withheld) assess the state of the frame and suspension + and was told that the vehicle has maybe 1 year or so until the frame falls apart. Given I am the original owner, have gargage-kept my vehicle, have very low-mileage - 74,000 miles, and have maintained the vehicle immaculately and am aware of rusting problems with other Toyota [truck] frames, etc. this seems to be a defect in the manufacturing process. I know there have been recalls on Toyota's other trucks due to Toyota's failure to add [enough?] rust inhibitor/preventative to the molten steel when forming the frame for many models of their trucks.

NHTSA ID

11438485

Incident

Oct 14, 2021

After having my 4 runner in for routine maintenance, my mechanic informed me that my frame was in bad condition and rusting through. Doubtful it has a year left and he advised me to junk it as fast as I can. 180;000 miles - so much for Toyota’s lasting a long time.

NHTSA ID

11424088

Incident

Jun 16, 2021

FRAME IS RUSTED. DEEMED UNSAFE TO DRIVE

NHTSA ID

11365850

Incident

Oct 5, 2020

Mileage

66,000 mi

THE VEHICLE IS IN IMPECCABLE CONDITION. THE FRAME IS RUSTED THROUGH IN THE AREA OF THE PASSENGER SIDE ABOVE THE TRAILING ARMS AND THE MIDDLE SECTION OF THE RAIL. I BOUGHT THE VEHICLE IN 2006 AND HAVE BABIED THE VEHICLE.

NHTSA ID

11355215

Incident

Sep 14, 2020

Mileage

295,000 mi

I FOUND FRAME RUST WITH PERFORATION ON MY 02 TOYOTA 4RUNNER

NHTSA ID

11353316

Incident

Sep 1, 2020

Mileage

166,000 mi

WHEN I HAD MY STATE INSPECTION IN JANUARY OF 2020, THE MACHANIC TOLD ME THE FRAME OF THE VEHICLE WILL NOT PASS INSPECTION AGAIN. IT IS SEVERELY RUSTED THROUGH AND IN HIS OPINION IS UNSAFE TO DRIVE. A FEW WEEKS LATER, I WAS TRAVELLING TO MY FATHER'S RESIDENCE AND THE BRAKES GAVE OUT. THE TECHNICIAN THAT REPAIRED MY BRAKE LINE ALSO TOLD ME AND DOCUMENTED ON THE BILL THAT THE TRUCK IS REALLY NOT SAFE TO DRIVE. I HAVE OWNED THIS VEHICLE FOR 18 YEARS, AND ONLY DRIVEN IT FIVE WINTERS. I WASH THE TRUCK NUMEROUS TIMES DURING THE WINTER TO REMOVE SALT. IT IS MY ONLY VEHICLE, AND I CANNOT AFFORD A NEW ONE. WHY WASN'T THIS INCLUDED IN THE FRAME RECALL FROM TOYOTA?!? NOW I'M NERVOUS ABOUT MY SAFETY AND THOSE ON THE ROADWAYS.

NHTSA ID

11317745

Incident

Mar 3, 2020

Mileage

146,000 mi

I HAVE A 2002 TOYOTA 4RUNNER WITH A SEVERELY RUSTED FRAME. MY VEHICLE HAS LESS THAN 70K ORIGINAL MILES ON IT, NO BODY RUST, BUT AN EXTREMELY RUSTED UNDERCARRIAGE AND FRAME. I FEEL IT IS UNSAFE TO CONTINUALLY DRIVE WITH THIS PROBLEM, AS IT WILL ONLY GET WORSE AND COULD AFFECT OTHER COMPONENTS SUCH AS STEERING, SUSPENSION, BRAKES, ETC. SEEING AS HOW TOYOTA HAS ALREADY HAD A CLASS ACTION LAWSUIT AGAINST THEIR TRUCKS OF THE SAME YEAR FOR UNSAFE RUSTED FRAMES, I FEEL MY 4RUNNER SHOULD BE INCLUDED IN THE FRAME REPLACEMENT RECALL.

NHTSA ID

11299973

Incident

May 13, 2019

RIGHT FRAME RAIL IS VERY RUSTED TO THE POINT OF NON REPAIR. UNABLE TO REPAIR SUSPENSION DUE TO UNABLE TO REMOVE BOLTS THAT HOLD SUSPENSION TO FRAME.

NHTSA ID

11208039

Incident

May 13, 2019

I WAS DOING AN OIL CHANGE AND NOTICED THAT THE FRAME WAS RUSTED VERY BADLY . I THINK THAT THERE SHOULD BE A RECALL ON THIS MODEL 3RD GEN 4RUNNER (1999-2002)THIS IS THE SAME FRAME AS THE TRUCK THAT WAS RECALLED ,SO THIS SHOULD BE INCLUDED .IF THIS FRAME BREAKS IT WILL HURT OR KILL SOME ONE .

NHTSA ID

11187330

Incident

Mar 11, 2019

Mileage

199,432 mi

ON MY 2002 TOYOTA 4 RUNNER THE BRACKET WELDED TO THE FRAME FOR REAR TRAILING ARM ON DRIVERS SIDE RUSTED OFF CAUSING THE VEHICLE TO SWAY AND ACT VERY STRANGE. LOTS OF OTHER PLACES RUSTED BAD ON FRAME ALSO!

NHTSA ID

11166049

Incident

Jan 2, 2019

Mileage

291,000 mi

REAR SWAYBAR RUSTED FROM FRAME CAUSING 4RUNNER TO WOBBLE EXCESSIVLY ALMOST CAUSING ME TO WRECK. THAT SIDE OF FRAME IS COMPLETELY RUSTED AWAY.

NHTSA ID

11143805

Incident

Oct 12, 2018

Mileage

208,000 mi

THIS IS YET ANOTHER COSTUMER OF THE 4RUNNER 3RD GENERATION COMPLAINING ABOUT THE FRAME RUSTING OUT. THERE NEEDS TO BE RESPONSABILITY FOR THE BAD FRAMES ON THIS YEAR 4RUNNER. MY FRAME HAS HOLES IN THE REAR CONTROL ARM ATTACHMENT AREA AND MORE RUST ALL THROUGHOUT ENTIRE FRAME. I'M DOING ALL I CAN TO KEEP MY FRAME FROM GETTING ANY MORE RUST ON IT AND KEEPING IT SAFE TO BE ON THE ROAD. I STRONGLY BELIEVE TOYOTA SHOULD ALSO HAVE A FRAME RECALL FOR THE 4RUNNER LIKE IT DID FOR THE TUNDRA TACOMA AND SEQUOIA FRAMES.

NHTSA ID

11141413

Incident

Apr 15, 2018

REAR AXEL IS RUSTED OFF THE FRAME, AND ROTTING, MECHANIC SAYS IT'S UNSAFE TO DRIVE

NHTSA ID

11130001

Incident

Sep 17, 2018

THE REAR BODY MOUNT BUSHINGS ARE COMPLETELY RUSTED AWAY AND DO NOT HOLD THE FRAME TO THE BODY DUE TO EXCESSIVE FRAME BODY RUST THRU OUT THE VEHICLE'S FRAME. MAKES NOISE WHEN TURNING OR GOING OVER BUMPS

NHTSA ID

11124130

Incident

Aug 2, 2018

Mileage

165,000 mi

FRAME RUST ON THE INSIDE PORTION FOR THE FRAME. 33" HOLE RUSTED THROUGH COMPLETELY ON PASSENGER SIDE. RUST CONTINUES ABOUT 80% OF THE WAY THROUGH THE REAR LOWER CONTROL ARM MOUNT. DRIVER'S SIDE HAS A SIMILAR AMOUNT OF SEVERE RUST THAT HAS WEAKENED THE STRUCTURAL INTEGRITY OF THE FRAME TO THE POINT WHERE IT IS NO LONGER SAFE TO DRIVE. SHOULD THE CO TROLL ARM MOUNT FINISH RUSTING THROUGH, THE AXLE WILL NO LONGER BE ATTACHED TO THE FRAME ON THAT SIDE. THERE IS NOTICBLE FLEX AND SOUND ASSOCIATED WITH THE FRAME ROT. IT IS ONLY A MATTER OF TIME BEFORE THE CONTROL ARM MOUNT DISCONNECTS COMPLETELY, OR THE FRAME BUCKLES.

NHTSA ID

11121804

Incident

Aug 20, 2018

Mileage

216,878 mi

FRAME RUSTED OUT, SIMILAR TO TACOMA PICK UP TRUCKS RECALL. ADDITIONALLY CLIMATE CONTROL HEATING, COOLING, FAN DEFECTIVE, POWER ANTENNA IN-OPERABLE.

NHTSA ID

11097773

Incident

Feb 22, 2014

Mileage

124,530 mi

TAKATA RECALL: I WAS DRIVING ON. FREEEWAY (5) FREEWAY AND BALL JOINTS BUSTED OFF AND LOST WHEEL AND SLID ABOUT 60 FEET BEFORE STOPING. BUSTED BREAK LINE AND BENT CONTROL JOINT.

NHTSA ID

11085188

Incident

Apr 15, 2018

Mileage

354,000 mi

TAKATA RECALL. I HAVE A RUSTY FRAME THAT NEEDS TO BE ADDRESSED FOR SAFETY REASONS I WAS DRIVING ON THE HIGHWAY AT 55 MPH FRAME CRACKED AND I ALMOST DIED BECAUSE OF IT TOYOTAS HAVE POOR FRAME THAT SHOULD BE RECALLED

NHTSA ID

10978709

Incident

Apr 10, 2012

Mileage

120,000 mi

TRACTION CONTROL SYSTEM MALFUNCTIONS INTERMITTENTLY WHILE DRIVING AROUND CURVES. SEVERAL TIMES WHILE DRIVING APPROXIMATELY 30-40 MILES PER HOUR ON A MOUNTAIN ROAD, THE ANTI SKID LIGHT ILLUMINATES WITHOUT WARNING ON A DRY PAVED ROAD WITH A SUBSEQUENT SUDDEN PULL TO THE RIGHT AND "GRINDING" NOISE. THIS HAS HAPPENED MULTIPLE TIMES WITHOUT WARNING. THE TOYOTA DEALER CAN NOT HELP, SINCE HE CAN NOT REPLICATE THE PROBLEM. THE LATEST OCCURRENCE PULLED THE VEHICLE ACROSS THE CENTER LINE INTO THE ONCOMING TRAFFIC LANE. (HAD THERE BEEN ONCOMING TRAFFIC THIS WOULD HAVE BEEN A SERIOUS ACCIDENT)

NHTSA ID

10886135

Incident

Jul 18, 2016

Mileage

181,900 mi

FRAME IS RUSTING OUT

NHTSA ID

10876064

Incident

Mar 15, 2015

Mileage

76,500 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

I HAVE A 2002 TOYOTA 4 RUNNER THAT WAS TAKEN IN FOR YEARLY STATE INSPECTION AND THE TECHNICIAN INFORMED THAT THE FRAME IS ROTTED THROUGH. HE STATED THAT THE VEHICLE WAS UNSAFE TO DRIVE AND A REJECTION STICKER HAS BEEN PLACED ON THE VEHICLE. NOT SURE WHAT TO DO NOW. THE VEHICLE STILL LOOKS AND RUNS VERY WELL, BUT UNABLE TO DRIVE.

NHTSA ID

10790501

Incident

Nov 5, 2015

Mileage

250,000 mi

VEHICLE WAS STATIONARY. WHILE REPLACING EXHAUST SYSTEM COMPONENTS. FOUND WHAT APPEARED TO BE MINOR RUST ON THE PASSENGER (RIGHT) SIDE REAR SUSPENSION MOUNT. FURTHER INVESTIGATION UNCOVERED A LARGER AREA OF RUST ALONG THE 3 WELDS ON THE INNER FRAME RAIL. CUT / GROUND THE METAL BACK TO GOOD METAL AND AM IN THE PROCESS OF PATCHING FOR MY YEARLY MAINE VEHICLE INSPECTION. EITHER TOYOTA HAS BUILT AN INFERIOR FRAME OR THE NEWER CHEMICALS BEING USED TO KEEP THE ROADS CLEAR IN THE WINTER TO BE THE CAUSE OF THIS RUST WHICH COULD CAUSE THE REAR SUSPENSION TO FAIL AT THIS POINT IN THE FRAME AND CAUSE A ACCIDENT.

NHTSA ID

10779459

Incident

Sep 30, 2015

Mileage

182,489 mi