2003 Toyota 4Runner 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.

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.

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.

There is severe rust on the frame, the rear is listing by 3/4 of an inch due to suspension rust, parts of the frame are perforated and lots of rust can fall out of drain holes when tapped. I am unable to steer the truck due to the intermediate steering column rust. The Tacoma was recalled for the same reason, I am assuming the 4runner has not been recalled because it was manufactured in greater numbers, and therefore more costly to repair, the danger of the severe rust is the same in both vehicles.

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.

The rust and corrosion underneath the vehicle continually gets worse year after year. The main components of vehicle relating to the engine, powertrain and suspension underneath vehicle are corroded; holes exist in the frame of the truck through out. The frame of truck is rotted due to not being sealed properly during the manufacturing process. Due to the rust and corrosion on the frame of truck, it is impossible to get work done on exhaust and muffler areas. I will send pictures for your reference. This makes driving a safety concern for myself and my son. At this time, I am unable to purchase a new car and do not have money to replace/fix the frame of truck. Inevitably, this problem will get worse and may cause a safety concern for myself and others on the road. I called Toyota on 4/12/22 and was told that there is not a recall for this issue and that any repairs would have to be paid by me. I then proceeded to call the number given to me by the representative to call 800-331-4331 for the Toyota Corporate office. I spoke to Blake who gave me the same answer, there was not a recall on this vehicle for rust/corrosion on the frame of vehicle. At this time, Toyota charges $150 just to check car and unfortunately, I don't have those funds to pay such a fee. I asked Blake if there was a way, Toyota can check without charging a fee and his answer was no. Currently, there is not any warning lights on, but with increased time and pressure of exhaust pipe and muffler will create more problems. I cannot have the exhaust system fixed until the frame of truck is replaced. My car was checked by an independent shop.

The VSC system in the vehicle becomes disabled due to a firmware 'glitch' identified by Toyota when an emission system issue is detected by the onboard diagnostic system. The VSC system is listed as an 'essential safety feature,' so I'm curious why a recall was never ordered to patch defective firmware that can cause VSC to become disabled due to a completely unrelated emissions issue.

Due to severe rust underneath the vehicle, there have been a few issues that have made the vehicle very unsafe to drive. Last week, both of my rear brake lines were completely done and leaking brake fluid leaving me with no brakes. This was due to rust and corrosion that had eaten the metal lines away. The radiator mounts are corroding, as well as the skid plate for my fuel tank and a few spots on my frame near the rear. I was not aware of the rust as I just got the vehicle a few weeks ago. I was driving in traffic when my brake light came on and I noticed my brakes didn't seem to be very effective and they eventually got the point where they were not working or slowing the vehicle at all. Once I took it to the shop and they put it on the lift, the mechanics pointed out just how bad the rust was.

The contact owns a 2003 Toyota 4Runner. The contact stated while his wife driving 60 MPH with the cruise control activated, the accelerator pedal was depressed, and the vehicle rapidly started to accelerate. The contact stated no warning light was illuminated. The driver depressed the brake pedal to stop the vehicle and parked on the side of the road. The driver was able to restart the vehicle and drive to her destination. The contact stated that in October 2021 his wife experienced a similar failure. The contact also stated that on 11/8/2021 while his wife driving 55 MPH and depressing the accelerator pedal, the vehicle accelerated quickly. The contact stated no warning light was illuminated. The driver depressed on the brake pedal with both feet and shifted gear to neutral to slow the vehicle. The driver stated she saw smoke coming from both front brakes. The drive was able to park on the side of the road. The driver stated that the brake pedal was seized on the floorboard. The driver stated she applied the parking brake to release the brake pedal. The driver was able to drive to her residence. The contact stated that his wife had experienced the failure on 3 different occasions. The vehicle was not diagnosed or repaired. A dealer was not contacted. The VIN was associated to NHTSA Campaign Number: 11V113000 (Vehicle Speed Control) and NHTSA Campaign Number: 03V146000 (Fuel System, Gasoline). The manufacturer had not been informed of the failure. The failure mileage was approximately 240,000.

The main rust issues are claims arising out of a pending class action lawsuit pleadings’ that the Toyota Manufacturer perform at no cost inspections, in addition to dire emergency needed replacement of including my 2003 Toyota 4Runner frame because of premature rusting of the undercarriage-my vehicle’s frame due to improper treatment against rust corrosion during manufacturing-inadequate rust protection, which has lead to severe excessive rust corrosion significant enough to affect structural integrity, compromising the vehicle’s safety, stability & crash-worthiness, & poses a dangerous risk.

There is severe rust on the frame, the rear is listing by 3/4 of an inch due to suspension rust, parts of the frame are perforated and lots of rust can fall out of drain holes when tapped. I am unable to steer the truck due to the intermediate steering column rust. The Tacoma was recalled for the same reason, I am assuming the 4runner has not been recalled because it was manufactured in greater numbers, and therefore more costly to repair, the danger of the severe rust is the same in both vehicles.

Stabilizer bar connecting the axle to the frame rusted off. I was driving only 25-30mph at the time, luckily. The vehicle swayed violently almost causing an accident and nearly forcing me off the bridge I happened to driving over. Very fortunate no one was hurt and nothing was damaged from the incident. You can imagine the tragedy if that had happened on the highway driving 75mph! Major accident, innocent lives damaged or lost. This is a very dangerous vehicle not only to the driver and passengers but also to anybody that happened to be innocently in the path of an out of control Toyota 4runner. Toyota Please fix this, for your safety and everyone else on the highway. People should be warned!!

Complete corrosion of entire frame causing unavoidable damage to framework.

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.

My vehicle: 2003 4Runner SR5 2WD VIN: [XXX] Issue: Front driver's side door will not open. Electronic locks are operating, but the door release is not functioning. Safety Concern: What if I was in a situation where I did need to get out of the vehicle immediately? Such as a high-water incident, fire, etc. Especially for a person [XXX], as myself, this would be a big issue. When attempting to exit the car after pulling into the driveway, I could not open the driver's door. The locks would release, but the door latch would not. I had to crawl over the console to get out through the passenger side. This was not easy as I had back fusion surgery and 8 disc replaced, fused. I had to open the sunroof to help with get over and out. After I did get out, I tried the key in the driver's door, it would actuate the door locks on all doors, but the driver's side door latch would still not release. I even disconnected the battery and reconnected. No help. And after knowing more, it was not an electrical issue, but mechanical failure. I now have it at the repair shop after talking with Toyota Service manage who admitted it was a poor design as the repair for this is to destroy the door panel to get to the actuator to attempt to release the door latch. The estimate for this work is 1,150.00. I am beyond frustration, and especially when I see there is no recall for this issue. There are penty of conversations on this same issue on 4Runner forums as well as all over YouTube. Thank you for looking into this. You can reach me at: [XXX] [XXX] [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

TL* THE CONTACT OWNS A 2003 TOYOTA 4RUNNER. THE CONTACT STATED THAT WHILE THE VEHICLE WAS PARKED, THE CONTACT NOTED THAT THERE WERE CRACKS IN THE DASHBOARD NEAR THE AIR VENTS. THE VEHICLE WAS TAKEN TO A DEALER WHERE IT WAS DIAGNOSED THAT THE DASHBOARD WAS CRACKING AND NEEDED TO BE REPLACED. THE MANUFACTURER ALSO SENT A LETTER ASKING OWNERS TO TAKE THE VEHICLE TO A DEALER TO HAVE THE DASHBOARD INSPECTED HOWEVER, THE DEALER STATED THAT THE REPAIR PART WAS NOT AVAILABLE. THERE WAS NO RECALL ON THE FAILURE. THE VEHICLE WAS NOT REPAIRED. THE APPROXIMATE FAILURE MILEAGE WAS 170,000.

I HAVE A 2003 4 RUNNER WITH ONLY 102375 MILES AND THE RIMS ARE CRUMBLING AWAY LIKE CHALK. THESE SHOULD NOT DO THIS, IT HAS TO BE DEFECTIVE MATERIALS AND SHOULD BE RECALLED BEFORE SOMEONE IS HURT OR WORSE. TOYOTA IS AWARE OF THIS PROBLEM AND WILL BE RESPONSIBLE AND THEY NEED TO RECALL AND FIX THEIR MISTAKE.

FRAME IS COMPLETELY RUSTED OUT. STEEL IS LITERALLY FALLING OFF FROM THE RUST AND MY SUSPENSIONS ARE COMPLETELY SHOT AND EXPOSED DUE TO RUST.

TL* THE CONTACT OWNS A 2003 TOYOTA 4RUNNER. WHILE ATTEMPTING TO LOWER THE FRONT DRIVER SIDE WINDOW, THE CONTACT HEARD A POPPING SOUND AS THE GLASS BECAME STUCK MIDWAY AND DID NOT MOVE UP. THE DEALER AND MANUFACTURER WERE NOT NOTIFIED OF THE FAILURE. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE APPROXIMATE FAILURE MILEAGE WAS 112,000.

TOYOTA INSTALLED A SUNROOF THAT HAD KNOWN DESIGN DEFECTS IN THE 2003 4RUNNER, THE FIRST MODEL YEAR OF THE 4TH GENERATION 4RUNNER. THE SUNROOF WOULD EVENTUALLY STOP WORKING, AND THE DRAINAGE TUBES IN THE SUNROOF WOULD CLOG AND BACK UP. THIS WOULD CAUSE WATER TO RAIN DOWN ON THE HEAD OF THE DRIVER AND FRONT SEAT OCCUPANTS DURING ACCELERATION OR A SUDDEN STOP. TOYOTA HAS KNOWN ABOUT THE SUNROOF ISSUE SINCE AT LEAST 2006, AND HAD ISSUED MULTIPLE TOYOTA SERVICE BULLETINS ON THE ASSEMBLY WITHOUT INITIATING A RECALL. *TR

Due to severe rust underneath the vehicle, there have been a few issues that have made the vehicle very unsafe to drive. Last week, both of my rear brake lines were completely done and leaking brake fluid leaving me with no brakes. This was due to rust and corrosion that had eaten the metal lines away. The radiator mounts are corroding, as well as the skid plate for my fuel tank and a few spots on my frame near the rear. I was not aware of the rust as I just got the vehicle a few weeks ago. I was driving in traffic when my brake light came on and I noticed my brakes didn't seem to be very effective and they eventually got the point where they were not working or slowing the vehicle at all. Once I took it to the shop and they put it on the lift, the mechanics pointed out just how bad the rust was.

No Accident - Items need to be investigated for Safety Defects on Toyota's. 1> Front Brake Calipers (constant freezing of the front brake calipers). 2> Dash Cover (excessive cracking on the dash covers especially areas that contain airbags). 3> Fuel Pump Connection (on top of fuel tank, connection to fuel pump appears to create a short, which in turn causes vehicle to stall also could cause a fire). 4> Excessive Frame Rust (frame has excessive rust outside and inside which is causing frame to fail. this is a manufacturing issue). These are ongoing issues with Toyota that have been reported and nothing is being done about it. Multiple 4runners are having big time Excessive Frame Rust, which are causing the frame coming apart during highway driving. These photo's show the rust on the outside and inside, all metal is having rust issues. Paint has been applied to cover said rust but it still reappears with-in a few months. Best way to contact me is via e-mail.

I PURCHASED THIS 4RUNNER IN MARCH, 2015. I BEGAN TO NOTICE A VIBRATION IN THE STEERING WHEEL AT 63MPH. I THOUGHT IT WAS BRAKES, I HAD BRAKES AND ROTORS SURFACED ON 3/12/15. STILL VIBRATING! SO I FIGURED IT WAS A SIMPLE BALANCING ISSUE, I TOOK IT ON THE SAME DAY TO HAVE IT BALANCED. IT STARTED VIBRATING AND SHAKING WORSE! I HAD THE SAME MECHANIC RE-BALANCE AND ROTATE THE WHEELS/TIRES. IT ROAD THE SAME. THEY TURNED ME TO THE TOYOTA DEALERSHIP BECAUSE THEY HAVE THE ROAD ENFORCE BALANCER. I TOOK IT TO TOYOTA TO HAVE THEM TEST DRIVE FIRST, THEY CLAIMED IT WAS INDEED OUT OF BALANCE. TOYOTA BALANCED. I DROVE IT AND IT WAS SHAKING LIKE A LEAF AT 32-70MPH. I HAD TOYOTA RE-BALANCE AGAIN! I DROVE IT AGAIN AND IT REMAINED WORSE. THEY INFORMED ME THAT THEY DIDN'T KNOW WHAT ELSE TO DO. I LEFT THINKING THAT IT WAS MY WHEELS AND OR MY TIRES BECAUSE IN MY MIND TOYOTA KNOWS BEST! I WENT TO WHERE THE TIRES WERE BOUGHT, TIRES ARE 3 MONTHS NEW. THEY INFORMED ME THAT THIS SAME 4RUNNER HAD BEEN BROUGHT IN BY THE PREVIOUS OWNER WITH THE EXACT SAME ISSUE. THEY PULLED THE WHEELS OFF AND PULLED ME ASIDE TO SHOW ME HOW EXCESSIVE THE BALANCING WEIGHTS WERE ON EACH RIM AND SOME ALL THE WAY AROUND RIM (TOYOTA'S DOING). THEY BALANCED USING THE HAWEKA, IT DROVE BETTER BUT STILL VIBRATING AT 32-70MPH. THEY RE-BALANCED AGAIN, STILL SAME ISSUE. THEY USED A DIFFERENT SET OF WHEELS AND BALANCED AGAIN, SAME ISSUE. THEY INSTALLED MY ORIGINAL WHEELS BACK ON AND RE-BALANCED AGAIN, SAME ISSUE! THEY CHECKED HUBS, BEARINGS, ALIGNMENT, BRAKES, ROTORS, BOOTS, AXLE AND EVERYTHING CHECKS OUT. I HAVE INVESTED NEARLY 4 DAYS AND $300 IN LOCATING THE ISSUE. I HAVE DONE RESEARCH AND SO MANY TOYOTA 4RUNNER OWNERS ARE COMPLAINING ABOUT THE SAME ISSUE. I AM CLUELESS AND DON'T KNOW WHAT ELSE TO DO. I AM RUNNING OUT OF PATIENCE AND MONEY! PLEASE HELP! *TR

2003 TOYOTA 4 RUNNER. CONSUMER WRITES IN REGARDS TO VEHICLE TIRES PROBLEM. *SMD THE CONSUMER STATED A FEW DAYS AFTER PURCHASING THE VEHICLE, SHE EXPERIENCED TWO INCIDENTS, WHERE SHE ALMOST LOST CONTROL OF THE VEHICLE WHILE DRIVING IN THE RAIN. THE CONSUMER WAS INFORMED THE TIRES, WERE SEVERELY WORN AFTER ONLY 20,000 MILES.

DASHBOARD IS CRACKING FROM SIDE TO SIDE; A FEW CRACKS ARE RIGHT OVER THE PASSENGER AIRBAG. I WORRY ABOUT THE INTEGRITY OF THE AIRBAG. IF ANYTHING MALFUNCTIONS, AT LEAST I'LL HAVE THIS COMPLAINT ON RECORD.

CAR WAS RUNNING PERFECTLY. BRAKES WERE SERVICES 6 MONTHS AGO. TRAVELED FROM NC TO FL FOR HOLIDAY. STARTED CAR MAINTENANCE LIGHT WENT ON SHOWED AIR BAG INDICATOR LIGHT WITH EAR PIERCING BUZZER. WENT TO DRIVE CAR TO TOYOTA SERVICE DEPARTMENT AND HAD NO BRAKES. THEY WOULD WORK SLIGHTLY BUT TO DANGEROUS TO DRIVE. DID NOT HAVE BRAKES

Odometer Fraud. The contact investigated a 2003 Toyota 4 Runner. The contact stated that during the investigation, he discovered a fraudulent scheme of approximately 15 vehicles with odometer fraud. The contact stated that the suspects targeted Facebook Marketplace victims by spraying oil on the engine prior to test-driving the vehicle, and when the vehicle began smoking, the suspects would ask for a discount for the vehicle. The contact added that after the vehicle was purchased, the odometer was rolled back and the vehicle was resold. The vehicle was a private sale. At the time of purchase, the vehicle mileage was 150,000, and at the time of the vehicle being sold, it was discovered that the mileage was 306,000.

THE REAR TIRE ASSEMBLY RIPPED LOOSE FROM ITS MOUNTS UNDER NORMAL DRIVING CONDITIONS..A LOUD CLUNK NOISE....THEN .BRAKES WERE LOST AND THE ELECTRICAL SYSTEM SHOWED WARNING LIGHTS ON DASH BOARD...CAR IS NOT DRIVABLE...MASSIVE RUST AT FAILURE POINTS

TL* THE CONTACT OWNS A 2003 TOYOTA 4RUNNER. THE CONTACT STATED THAT THE SUBFRAME WAS RUSTED, CAUSING THE TRANSMISSION TO HANG VERY LOW. AS A RESULT, THE VEHICLE WAS INOPERABLE. THE VEHICLE WAS TOWED TO THE DEALER WHERE THE TRANSMISSION WAS RE-ATTACHED. THE MANUFACTURER WAS AWARE OF THE FAILURE. THE FAILURE AND CURRENT MILEAGES WERE 129,000. ..UPDATED 09/19/11 *BF ALSO, THE STEERING INTERMEDIATE SHAFT NEEDED TO BE REPLACED. UPDATED 10/28/11

WHEN COMING TO A STOP AND/OR ACCELERATING FROM A STOP THE CAR WILL JERK FORWARD WITH A THUD. SOMETIMES TWO OR THREE THUDS ARE FELT AND HEARD. THE DEALER WITNESSED THIS PROBLEM AND OURISMAN TOYOTA IN CHANTILLY, VA REPLACED THE TRANSMISSION AT 14,500 MILES. THE PROBLEM SEEMED TO GO AWAY FOR A WHILE. I RETURNED TO THE SAME DEALER WITH THE SAME COMPLAINT AT 32,000 MILES AND THEY REPLACED THE DRIVE SHAFT. I RETURNED AGAIN ON 11/30/04 AND THE SERVICE MANAGER WITNESSED THE SAME PROBLEM WITHIN 200 FEET OF DRIVING. THE SERVICE MANAGER INDICATED HE BELIEVES THIS IS NORMAL (EVEN THOUGH THIS WAS NOT A PROBLEM TILL ABOUT 12,000 MILES). HE IS GOING TO DISCUSS THIS WITH THE TOYOTA REP WHO IS IN TOWN THIS WEEK.*AK I

FRAME HAS SIGNIFICANT RUST AND HAS DEVELOPED A HOLE UP NEAR THE FRONT OF THE CAR. I'VE HAD THE RUST SANDBLASTED OFF AND THE FRAME RE-COATED, BUT SHOULD THE FRAME FAIL, IT COULD RESULT IN A REAL SAFETY PROBLEM. DRIVER SEAT BELT DOES NOT RETRACT PROPERLY, WHICH COULD RESULT IN THE SEATBELT NOT BEING SNUG ENOUGH TO PREVENT INJURY IN THE EVENT OF AN ACCIDENT

REAR LEFT SAFETY BELT DOES NOT RETRACT. THE VEHICLE HAS NOT BEEN ALTERED OR DAMAGED IN ANY WAY PRIOR TO SAFETY BELT NOT RETRACTING. CAN NOT USE REAR LEFT SAFETY BELT. SAFETY BELT IS FULLY EXTENDED AND WILL NOT RETRACT. *TR