2003 Toyota 4Runner Body & structure Problems

Severe frame rust. 2 large holes on the inside of the frame just back from the front wheels and 2 large holes at the ends of the rear crossmember.

NHTSA ID

11711459

Incident

Jan 1, 2026

Toyota has had issues with their frames rusting out and the 4th generation 4Runner is not exempt from this issue. My 2003 is requiring extensive work to keep it on the road safely due to frame rust. A recall to replace frames should be in place.

NHTSA ID

11619222

Incident

Jan 1, 2024

There is major corrosion on the chassis, brake-power steering-transmission lines, and all metal brackets on the frame and engine. The corrosion is so bad there is holes on the chassis. Known issue, many complaints, Toyota Corp. says to keep calling back maybe something will be done in the future. Unable to upload photos!

NHTSA ID

11561325

Incident

Apr 1, 2017

Severe frame rust, there was a recall for tacomas but 4Runners have the issue just as bad

NHTSA ID

11551123

Incident

Oct 20, 2023

The contact owns a 2003 Toyota 4Runner. The contact stated that upon taking the vehicle to several independent mechanics for servicing, he was informed that the subframe was significantly corroded and needed to be replaced. The vehicle was not repaired. The dealer was not notified of the failure. The manufacturer was notified of the failure and informed the contact the vehicle was not covered under recall. The failure mileage was approximately 115,000.

NHTSA ID

11537118

Incident

Aug 8, 2023

Mileage

115,000 mi

The contact owns a 2003 Toyota 4Runner. The contact stated that while the vehicle was at the tire retailer for tire replacement, the technician informed him that the subframe was corroded. The vehicle was then taken to an independent mechanic, who diagnosed that the passenger's side front and rear subframes were severely corroded, as well as the cross member. The mechanic advised the contact to stop driving the vehicle. The dealer was made aware of the failure and informed the contact that there was no recall associated with the VIN. The vehicle was not repaired. The manufacturer was not made aware of the failure. The failure mileage was approximately 165,000.

NHTSA ID

11503828

Incident

Jan 12, 2023

Mileage

165,000 mi

Extensive rust through out frame, resulting in holes in structural members. Leaving frame in a weak and vulnerable state.

NHTSA ID

11501555

Incident

Sep 20, 2022

I purchased this 2003 Toyota 4Runner in 2018 under what I assumed was prime condition, for a vehicle that spent the majority of its life in Nebraska/Kansas before I moved to Texas in 2021. At 87,400 miles at the time of purchase, the vehicle had no visible damage to the exterior besides a few paint chips, some minor hail damage and scratches, and some easily fixed surface rust in the paint on the tailgate. The previous owner had driven it leisurely and had kept the miles low after 15 years. The car has had some mechanical issues, but nothing out of the ordinary outside of some regular maintenance over the first few years. Being close to 100,000 miles, the timing belt and pump was replaced around 98,000 miles. Other issues have been fixed periodically, please reference the attached files. After joining a Toyota 4Runner 4th Generation Facebook group and seeing a post about another's issues with rust damage in October 2020, I decided to take a look at my own frame. I then inspected my own vehicle, and found significant frame rot damage. It is extensive, with significant rust to the frame, with large holes and soft patches that question the integrity of the frame and the safety of the vehicle on the road. Every time I hit a small bump or pothole, I fear the frame will crack and I will lose control as others have. I have not sought out professional repairs due to the extensive cost, and am awaiting the outcome of a current class action lawsuit by the Bell Legal Group. The 4th Generation Toyota 4Runner (2003-2009) is built on the exact same frame as the Toyota Tacoma of that era, yet while the Tacoma was recalled for frame rot, the 4Runner was not included, which I believe to be a gross oversight in previous legal proceedings. The 2003-2009 Toyota 4Runner is a reliable vehicle, but poses significant frame rot issues much earlier than should be expected.

NHTSA ID

11500005

Incident

Oct 1, 2020

Vehicle frame has rusted through and has holes affecting structural condition.

NHTSA ID

11495953

Incident

Nov 28, 2022

Excessive frame rust causing difficulty to keep vehicle on the road. No warning lamps, I noticed the rust starting years ago, now the rust is so bad that the frame is rusted through causing difficulty steering and loud crunch noises. I contacted Toyota Consumer Affairs explaining the rust concern and asked if I needed to take the vehicle to a dealership for inspection, they said it wasn’t necessary (sounds like they don’t want to admit the existence of a possible manufacturing defect). The vehicle is available for inspection. I feel like I would be doing a disservice to society if I continue to drive this vehicle on public roads due to the danger of injuring a pedestrian or another motorist.

NHTSA ID

11479718

Incident

Aug 10, 2022

So much rust has developed the frame is literally giving out. Toyota admitted to a rust issue- it’s now a safety issue with this generation of 4Runner. They did a recall on the same frame for Tacoma but not 4Runner.

NHTSA ID

11470783

Incident

Jun 23, 2022

The frame of the car has been rusting at a significant rate in the last 4 years. Mechanic identified major rust issues that would make the vehicle not safe in case of an accident.

NHTSA ID

11463988

Incident

May 10, 2022

I have two 2003 Toyotas, a tundra and 4runner. The 4Runners frame is rusting out everywhere including the welds. My mechanic said it was getting to the point that it’s dangerous to drive and if it was in a wreck the frame would likely fail under the stress. My tundra frame from the same year is immaculate. I believe the are similar frames. This is obviously a defect in the production based on my readings and is very common. The investigation was opened in 2018 and its now 2022, when will this get addressed!

NHTSA ID

11459345

Incident

Feb 7, 2022

Frame has major rust holes towards the front inside next to the catalytic converters. Hoping to get them repaired before frame failure. The frame design is similar to the 2005 to 2015 Tacomas, which experienced similar issues with rust damage causing frame integrity issues. Toyota had a program to replaced those frames, but not for the 4Runners. The issue seems to be caused by certain factory openings in the frame that allow road salt to enter into the frame cavity, and cause the inside to rust. Being next to the catalytic converter, the heat accelerates the rust. On my 4Runner, the issue has gotten worse in the last 2 years. I cannot understand why Toyota covered all other trucks/suvs that use this similar frame but ignored the 4Runner.

NHTSA ID

11458884

Incident

Mar 1, 2016

The frame on my 4Runner is rusting through in multiple locations. The rear of the frame has already failed and a trailer I was pulling dragged on the road heavily as it failed. Definitely at risk of caving in long before the engine or transmitoo fails.

NHTSA ID

11458230

Incident

Mar 24, 2022

The frame on my vehicle is rusting prematurely. It's doing this on many other 4Runners and other Toyota trucks.

NHTSA ID

11448877

Incident

Feb 4, 2021

The frame of the vehicle is rusted to the point my fist can fit through a hole in the frame.

NHTSA ID

11439132

Incident

Nov 2, 2021

The frame on the vehicle is rusting out. If not repaired, serious injury could occur if the frame breaks. A compromised frame could cause serious injury if an accident occurs. The driver side main frame has a gaping hole on the inside and another hole forming underneath that is in close proximity to the larger hole. The entire back cross bar member supporting the bumper is rusting out as well as the front cross bar member. The vehicle was inspected in July 2020 and the dealership said the frame was OK and had plenty of life left in it. After getting a muffler installed at a local independent shop in October 2021, the hole grabbed the attention of the technician. After inspecting, rusty flakes kept falling away.

NHTSA ID

11437422

Incident

Oct 12, 2021

Extreme frame rust. The vehicle has extreme frame rust and Toyota should be held accountable for poor quality frame material. I have heard tons of stories of other peoples steering components snapping due to rust and frame damage.

NHTSA ID

11435309

Incident

Oct 3, 2021

I own a 2003 Toyota 4Runner with very low mileage for its age. It has been garage kept for most of its life. I was experiencing difficulty steering, and when I took the car to a mechanic, it was determined that the frame was prematurely rusted and rotted to a dangerous level putting my life at risk while driving it.

NHTSA ID

11434215

Incident

Apr 15, 2021

The frame is rusted very bad and it’s a major safety issue for this type of vehicle I don’t know when it’s going to fall apart. I am sure I am not the only one to have this problem.

NHTSA ID

11434037

Incident

Aug 20, 2021

Vehicle frame and suspension components are completely rusting out. Having issues with the corroded steering column lower shaft not allowing the vehicle to turn properly.

NHTSA ID

11433481

Incident

Sep 18, 2021

The contact owns a 2003 Toyota 4Runner. The contact stated that while driving at limited speeds of 45 mph, the vehicle would wobble and swerve and was very unstable. The vehicle was taken to a Certified Auto Mechanic Shop and an independent mechanic who diagnosed that the failure was caused by severe rusting, perforation and corrosion of the rear subframe and suspension system. The vehicle was also driven to Muffler Shops in Bladensburg, MD on 8-20-2021, and on 10 -22-2021 to Hyattsville Toyota's Certified Toyota Collision Center for Repair Estimates of $4,000.00 and $7,268.00. The vehicle frame manufactured by Dana Holding Corporation which really requires fixing or replacing was not yet repaired. The Toyota manufacturer and local dealer Global Auto Outlet were notified of the failure. The approximate failure mileage was 1 85,000. The used vehicle was purchased from Global Auto Outlet in Temple Hills, MD for $9,552.24 on 8 -1-2019 with 175,000 miles on the odometer. The windshield had a crack in it, the air conditioning & emergency brake didn't work. The Complainant hadn't noticed the perforated excessive rust corrosion on the undercarriage of the vehicle until numerous months afterwards. Moreover, at the time of the purchase the Owner also didn't notice that the spare tire carrier was rusted, as well as undiscovered that the wrong size 265/65/17 spare tire it was held in was perforated and flat. After the purchase of the vehicle shortly later, the exhaust tailpipe rusted broke first and the muffler had to be replaced which costed $258.79. The Owner was nervously forced to operate a more than unsafe motor vehicle for up to 6 months.

NHTSA ID

11432719

Incident

Sep 1, 2020

Mileage

185,000 mi

At the end of June 2021, while driving I experienced a loud clunk and grinding noise, with reduced control of steering and brakes on my 4Runner. I took the 4Runner to a Goodyear Automotive Service Center on Woodward Avenue in Royal Oak, Michigan, who told me that the vehicle was not driveable due to severe rust damage of the frame that resulted in a broken sway bar. I thought I should take it to the closest Toyota dealership in Troy, Michigan for advice and they responded that the vehicle was beyond repair and that a new frame would cost around $20,000. I could not leave my car there, and risked driving it home, where it has been parked ever since.

NHTSA ID

11431046

Incident

Jun 29, 2021

The frame of my 4runner is so so rusted that my mechanic put his finger through a piece of the frame it is so unsafe for Mr and my grand children and EVERYONE ELSE on the road that it literally makes me sick. It'd the only vehicle I have so I have NO CHOICE but to drive it. It terrifying. It is available to inspect at anytime. I just bought this vehicle less than a year ago from a dealership and it so sad that they wld sell it to anyone knowing the frame was rusted its criminal in my opinion. It Is for sure a safety hazard to everyone. I hope that this investigation proves to help get all of these 4runners OFF THE ROAD. So that a preventable tragedy doesn't happen.

NHTSA ID

11430563

Incident

Dec 18, 2020