2004 Toyota 4Runner Body & structure Problems

What component or system failed or malfunctioned, and is it available for inspection upon request? Response: Frame, Suspension, Airbags / Yes it is available for inspection. How was your safety or the safety of others put at risk? Response: Safety was put at risk due to frame & suspension failure due to severe rust. Also due to failure of deployment of AirBags. Rusted Frame Failure subsequently caused safety of Injured Party and other motorists to be at risk due to the Injured Party’s 4Runner to dart across oncoming lane of traffic with no warning other than a swaying motion felt immediately before losing control. Once the Injured Party lost control of the 4Runner it crossed into oncoming traffic, progressing into the drainage ditch on the oncoming traffic side of highway. Once the 4Runner impacted the drainage ditch at a 90° angle, the 4Runners momentum dispersed by causing the 4Runner to overturn 3 times landing on its wheels in the adjoining field. Has the problem been reproduced or confirmed by a dealer or independent service center? Repaonse: Independent Service Center has confirmed the problem with the Rusted Frame, Rusted Suspension, and Air Bag failure. Has the vehicle or component been inspected by the manufacturer, police, insurance representatives or others? Response : Yes Were there any warning lamps, messages or other symptoms of the problem prior to the failure, and when did they first appear? Repaint: No warning lamps prior to failure. Symptoms indicative of failure were an unknown minor swaying sensation while driving. Injured party was under the impression that there may have been a tire low on air, which was discovered to be incorrect later.

NHTSA ID

11707650

Incident

Dec 28, 2025

The contact owns a 2004 Toyota 4Runner. The contact stated that while the vehicle was in for service, the independent mechanic discovered rust on the front driver's side subframe. Additionally, the subframe had developed holes due to rust. The cause of the failures was not yet determined, and the vehicle was not yet repaired. The manufacturer and local dealer were notified of the failure, but no assistance was offered. The failure mileage was 120,000.

NHTSA ID

11683937

Incident

Aug 29, 2023

Mileage

120,000 mi

The contact owns a 2004 Toyota 4-Runner. The contact stated that the frame was severely rusted. The vehicle was not diagnosed or repaired by an independent mechanic or a dealer. The manufacturer was notified of the failure and referred the contact to the NHTSA Hotline for assistance. The failure mileage was approximately 108,000.

NHTSA ID

11681545

Incident

Aug 19, 2025

Mileage

108,000 mi

2004 Toyota 4Runner SR5 - Frame rust: currently not drivable due to complete breakage from the rust. Driving 2 hours home on the highway I almost lost control, pressing/releasing the brake and/or gas pulls the steering side to side and sways the truck (fish tail) due to damage from the frame rust/breaking. There is no control of the rear end. Truck was in great condition prior to the frame snapping. Vehicle has been inspected by multiple mechanics (including Firestone, Welding/fabricating Auto Repair shops and small owned mechanic shops), possibly won’t be able to weld due to the amount of rust. Firestone won’t perform any service if the vehicle needs to go in the air (tires, oil..etc) due to frame rust. This has been a huge problem with Toyota, they addressed other models around the same year but excluded the 4Runner for unknown reasons. The dealership will not address the issue unless instructed by corporate. This problem jeopardized my safety and the safety of others around while I was driving at highway speeds, there was no warning when it occurred. Vehicle is available for inspection any time, as it currently is not going anywhere without a tow.

NHTSA ID

11679499

Incident

Jul 27, 2025

Frame rust. Huge problems on the 4th gen 4runners. Can't believe there's not a recall on this issue.

NHTSA ID

11669616

Incident

Jan 1, 2025

The undercarriage is full of rust that the repair shop will not test drive or fix due to the issue. No warnings.

NHTSA ID

11645055

Incident

Oct 17, 2022

Extensive frame rust to the point of structural failure. Cannot support weight or force.

NHTSA ID

11641362

Incident

Nov 29, 2024

Rusty frame undercarriage. It’s not going to get any better due to the fact I have to drive on hwy 80 with all the construction, that’s a hazard itself, potholes everywhere that puts stress on your frame and the salt every winter.

NHTSA ID

11620842

Incident

Nov 15, 2016

UNKNOWN: Excessive frame rust. frame is excessively rusting to the point where the brakes and suspensions is connected to the frame has been compromised. brake lines rusted to the point of failure, thus almost causing a wreck. Vehicle is now parked due to safety concerns involving the excessive rusting that is happening to the frame and any components that is attached to the frame.

NHTSA ID

11615836

Incident

Mar 6, 2024

Undercarriage frame rusted to the point where structural rust was formed in various places This rust has made a whole and cracks to the frame causing my vehicle to become a safety hazard on the road

NHTSA ID

11615331

Incident

Sep 18, 2024

Cars frame is rotting out to the point it is not safe to drive. I was told being in a collision could cause catastrophic failure and the car is just turning 20 years old with 125,000 miles. Can’t get my money back and the car is otherwise is excellent condition.

NHTSA ID

11603298

Incident

Jul 17, 2024

Took 2004 Toyota 4Runner SR5 to Toyota dealership to be serviced. Dealership called me to explain unable to do alignment, due to rear back frame excessive rusted through. Dealership advised waste of money to align new tires just purchased, unable to even do alignment and it was dangerous. Now what is to be done? This is my daily driver for work. How did this happen that its unsafe and dangerous to drive.

NHTSA ID

11578947

Incident

Mar 21, 2024

The rear tailgate window shattered while vehicle was in driveway as soon as it was turned off. Before it shattered there was an odor of something like plastic burning. Fortunately no one was hurt by the exploding bits of glass. The sound the breaking glass make was loud and startled the passengers. Good thing the vehicle was not in motion on the street or highway. On the internet I saw where other people shared the same problem on their Toyota 4Runner. Then I saw that Toyota had put out, TSB-0189-17, which stated exactly what happened to my 4Runner. Due to this possibly dangerous incident this should be upgraded to a vehicle safety recall.

NHTSA ID

11572821

Incident

Feb 18, 2024

2004 4Runner rear hatch glass imploded with rear defroster on while driving and glass shattered all inside the vehicle in the back behind rear passenger seat. The loud sound when it imploded sounded like we had got shot at and scared all four of us in the vehicle thinking we were shot at. We pulled the vehicle over at the nearest pull over while driving on a coastal two lane road. We searched for any possible bullets. Did not find any and had to clean up as much possible of shattered glass that had covered all of our clothing and belongings. Had no materials to cover the rear broken window and had to continue our drive to meet family members to attend an early event at 9:00 am.

NHTSA ID

11572654

Incident

Feb 18, 2024

Unknown: we were on [XXX] when the car went out of control. It first spun one way and then the other way and then we hit the concrete abutment where the guardrail connects to it. We hit it head on. It was as if we were on ice or oil, unable to gain control or brake. We checked the road and it was dry. Other cars were going by with no problem. The airbags didn’t deploy. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11559940

Incident

Dec 11, 2023

Rusted frame

NHTSA ID

11553609

Incident

Nov 4, 2023

The frame of the vehicle rust just as same as the 03-09 Tacoma and there is nothing I can do the fix it and if I get new parts it ruins my Parts after a short period of time

NHTSA ID

11538131

Incident

Aug 12, 2023

The contact owns a 2004 Toyota 4Runner. The contact stated while driving 30 MPH over a bump in the road, she heard an abnormally loud sound and the windshield shattered without impact and the sunroof panel loosened. The contact also stated that the vehicle was shaking uncontrollably. The contact stated that the traction control warning light was illuminated. The contact took the vehicle to the local dealer, where it was diagnosed and determined that the subframe was rusted and needed to be replaced. The vehicle was not repaired. The manufacturer had been informed of the failure. The failure mileage was approximately 160,000.

NHTSA ID

11532660

Incident

Jan 1, 2021

Mileage

160,000 mi

The frame of my Toyota 4-Runner has developed holes making it dangerous to drive.

NHTSA ID

11512004

Incident

Mar 15, 2023

The contact's mother owns a 2004 Toyota 4-Runner. The contact stated that after the vehicle was taken to an independent mechanic for a routine oil change, his mother was made aware that the subframe had excessive corrosion, and that the subframe needed to be replaced. The mechanic informed the contact's mother that the vehicle was not safe to drive. The vehicle was not repaired. The manufacturer was not made aware of the failure. The failure mileage was 180,330.

NHTSA ID

11509335

Incident

Feb 20, 2023

Mileage

180,330 mi

The contact owns a 2004 Toyota 4Runner. The contact stated that while the vehicle was in for routine service, it was discovered that the subframe had sustained severe rusting and corrosion. The contact indicate that there was a hole going through the subframe while the vehicle was being lifted at the service center. The local dealer and manufacturer were notified of the failure and informed the contact that the VIN was no longer covered under the Manufacturer’s Extended Warranty coverage for the failure. The approximate failure mileage was 146,000.

NHTSA ID

11506363

Incident

Feb 1, 2023

Mileage

146,000 mi

Frame and body prematurely and aggressively rusted despite constant care and upkeep. Toyota recalled the exact frame on their Tacoma of the same years and did not recall the 4runner frames. It’s criminal and dangerous to the user and other vehicles on the road.

NHTSA ID

11500557

Incident

Dec 5, 2022

-The frame is rotted out - If the frame were to break, which my mechanic i saying is very possible, a massive incident could occur - It has been confirmed by an independent service center - It has not been inspected by the manufacturer but is an astonishingly common issue Toyota is very aware of that they continue to ignore. - There were not indicators notifying me of the issue. I wanted to replace my suspension and the mechanic advised not doing so because of the rot.

NHTSA ID

11493961

Incident

Nov 17, 2022

The frame is damaged from excessive corrosion. The rear cross member that supports the trailer hitch and rear bumper is almost non-existent, which could result in the loss of the trailer being towed, and it will reduce the truck's rear impact resistance. The front right lower control arm has a 2'" x 3/8" lateral hole from corrosion, which could result in a catastrophic failure of the right front suspension system. The longitudinal frame members are compromised by corrosion which has penetrated through the steel in various locations. The front cross-frame member that supports the radiator is severely corroded. The frame to body mounts are showing signs of excessive corrosion which could result in the separation of the the body from the frame in an accident.

NHTSA ID

11490128

Incident

Oct 20, 2022

The frame is showing significant rust damage throughout the frame. A hole was punctured in the passenger side while using the factory bottle jack. This could have ended badly if someone was underneath when this happened. Furthermore there is deterioration on the front and rear sections that are questionable as to their integrity and resilience in the event of a crash. It is generally accepted by other owners of this generation that lack of adequete drainage throughout the frame has led to water pooling inside and creating excessive rust issues from the inside out.

NHTSA ID

11485903

Incident

Sep 15, 2022