2004 Toyota 4Runner Powertrain (other) Problems

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

TRANSMISSION WOULD NOT SHIFT IN MOTION LEAVING FROM A STOP SIGN. I LATER FOUND OUT MY TRANSMISSION LINES HAD CORRODED AWAY LEAKING A LARGE AMOUNT OF TRANSMISSION FLUID. AFTER REPLACING BRAKES AND ADDING BRAKE FLUID I NOTICED THE BRAKE FLUID HAD LEAKED FROM BOTTOM. I HAD TO REPLACE ALL BRAKE LINES AND FITTINGS DUE TO CORROSION.

NHTSA ID

11322167

Incident

Apr 22, 2020

Mileage

190,000 mi

EXCESSIVE FRAME RUST. REPLACED COMPLETE REAR END IN 2013. TOLD BY HYANNIS TOYOTA THAT IT WAS UNSAFE TO DRIVE BECAUSE OF EXCESSIVE RUST. THE REAR END IS NOW RUSTED OUT AGAIN IN 2019 AND NEEDS REPLACING. IN APRIL 2019 COULD NOT HAVE SUSPENSION REPLACED UNTIL FRAME WELDING WAS COMPLETED. ADDITIONAL WORK OF CUTTING OUT REAR UPPER TRAILING ARM BRACKETS AND WELD IN PLACE AND FABRICATE FUEL TANK STRAP MOUNT AND WELD IN PLACE. COMPLETE FRAME AND UNDERSIDE OF THIS VEHICLE IS COMPLETELY RUSTED OUT. WE HAD THIS WORK DOWN BECAUSE THE GAS TANK WAS FALLING OUT AND WE COULD NOT DRIVE THIS VEHICLE.

NHTSA ID

11203339

Incident

Apr 11, 2019

Mileage

150,000 mi

RUMBLE WHEN OVER 20 MPH AND TURNING SLIGHTLY RIGHT ON ANY SURFACE.

NHTSA ID

11194792

Incident

Feb 1, 2019

Mileage

94,500 mi

TAKATA RECALL FRAME IS COMPLETELY RUSTED. CAUSING ALL THE UNDERCARRIAGE TO RUST OUT AND MAKE THE VEHICLE VERY DANGEROUS TO DRIVE. EVEN THE BODY IS STARTING TO RUST AWAY. ONLY HAS 116,000 MILES ON IT WHICH IS CRAZY.

NHTSA ID

11184991

Incident

Sep 20, 2018

Mileage

116,000 mi

TRANSMISSION FAILED DUE TO RUSTED TRANSMISSION LINES. LEADS UP TO FINDING OUT THAT FRAME IS COMPLETELY RUSTED OUT. UNABLE TO FIX IT DUE TO FRAME RUST. SUSPENSION ARE OF FRAME RUSTED AS WELL...BARELY HOLDING ON. TRAVELING FROM TN TO PA WHEN ALL THIS HAPPENED.

NHTSA ID

11169986

Incident

Nov 30, 2018

Mileage

120,000 mi

PARTS OF THE VEHICLES EXTERIOR AND INCLUDING FRAME AND SUBFRAME COMPONENTS ARE EXCESSIVELY RUSTED. PARTS ARE OF THE SUSPENSION AND OTHER HARD PARTS ARE HAVING TO BE REPLACED DUE TO CORROSION.

NHTSA ID

11152351

Incident

Nov 1, 2018

Mileage

120,000 mi

OIL LEAKING FROM TRANSFER CASE ACTUATOR MOTOR ASSEMBLY POWERTRAIN TRANSFER CASE. VEHICLE IS STATIONARY

NHTSA ID

10911381

Incident

Sep 5, 2016

Mileage

170,450 mi

RUST EAT MY FRAME INTO

NHTSA ID

10861247

Incident

Apr 10, 2016

Mileage

220,000 mi

I HAVE AN ONGOING PROBLEM WITH OUR 2004 TOYOTA 4RUNNER. IT STARTED ABOUT 4 YEARS AGO WHEN THE MARYLAND STATE EMMISSION TEST FACILITY PLUGGED INTO MY ODBI2 PORT. ALL THE DASH LIGHTS WERE ON AND I WENT IN TO THE OFFICE AND COMPLAINED. I FILED A FORM WITH EMISSIONS. I WORK OUT OF TOWN, MY WIFE IS A TEACHER AND WE HAVE TWO SMALL KIDS. GOING TO THE DEALER WAS NOT AN OPTION UNTIL SCHOOL WAS OUR. IN THE MEAN TIME THE TRUCK DROVE FINE OTHER THAN NO FOUR WHEEL DRIVE AND THE TIRES SPINNING IF YOU HIT THE PEDDLE TO HARD (NO TRACTION CONTROL OR STABILITY CONTROL. TOOK THE TRUCK TO THE DEALER OVER THE SUMMER AND THEY HAD TO RESET THE VALUES FOR $110.00 THE FOUR WHEEL DRIVE WOULD NO LONGER ENGAGE. TOYOTA DEALER SAID ALL THE VALUES BEING ERASED WAS A COMMON PROBLEM WITH THAT YEAR AND MVA CHEEP SCANNERS. MARYLAND SAID THEY CALLED TOYOTA AND NO ONE HAD EVER HAD THAT PROBLEM. HAVE HAD THIS HAPPEN AGAIN LAST EMISSION TEST. BIGGEST PROBLEM IS THAT THE 4 WHEEL DRIVE NO LONGER FUNCTIONS. THE ACTUATOR DOESN'T ENGAGE THE 4 WHEEL DRIVE. THIS WAS APPARENT WHEN MY WIFE LOST CONTROL AND NEARLY FLIPPED THE TRICK OVER AFTER PICKING UP THE KIDS IN A SNOW STORM. I CLIMBED UNDER THE TRUCK IN THE SNOW AND PULLED THE COVER OFF THE ACTUATOR, PULLED OUT THE PLASTIC GEARS AND MANUALLY SHIFTED IT INTO 4 WHEEL DRIVE TO GET IT HOME. THE FOUR WHEEL DRIVE SYSTEM WAS ALWAYS USED AT LEAST EVERY MONTH UNTIL THE EMISSION TEST PROBLEMS JUST TO KEEP IT LUBERICATED. THE 4 WHEEL DRIVE OR LACK THERE OF, COULD HAVE CAUSED DEATH OR SERIOUS INJURY TO MY WIFE AND KIDS. THIS ACTUATOR IS A SERIOUS PROBLEM, IF THEY CAN'T DESIGN A ACTUATOR THAT OPERATES WHEN YOU NEED FOUR WHEEL DRIVE, ESPECIALLY IN AN EMERGENCY THAN GO BACK TO THE OLD STICK AND LINKAGE. 55 PEOPLE DIED IN THE BLIZZARD OF 2016 AND THERE COULD HAVE BEEN 3 MORE JUST BECAUSE OF A DESIGN FLAW! P.S. MY WIFE AND I BOUGHT IT NEW, NEVER OFF ROAD!

NHTSA ID

10837656

Incident

Jan 22, 2016

Mileage

79,000 mi

THERE IS EXCESSIVE RUST/CORROSION ON THE FRAME OF THE TRUCK. THE SKID PLATES COMPLETELY RUSTED OFF THE TRUCK IN 2010. THE TRANSMISSION LINES HAVE CORRODED TO THE POINT THEY HAVE TO BE REPLACED. THE ENGINE OIL COOLER AND RADIATOR SUPPORTS HAVE RUSTED THROUGH. THE EXHAUST RUSTED OFF THE TRUCK IN 2010 AS WELL. CURRENTLY THERE IS EXTENSIVE CORROSION ON THE FRAME OF THE TRUCK AND THE SUSPENSION COMPONENTS. THESE ISSUES APPEARED IN 2010 AND I HAVE BEEN FIGHTING THEM EVER SINCE. MECHANICALLY THE TRUCK RUNS GREAT, NEVER A PROBLEM, HOWEVER THE VEHICLE'S FRAME IS DISINTEGRATING DUE TO CORROSION.

NHTSA ID

10820610

Incident

Jan 16, 2016

Mileage

70,000 mi

I WAS GOING 5 MPH AND HIT MY BRAKES. THE CONTROL ARM WAS RIPPED FROM THE FRAME DUE TO ROT/RUST. TOYOTA IS AWARE OF THIS PROBLEM FOR 4RUNNERS, BUT HAS ONLY OFFERED ASSISTANCE ON THE TACOMA AND TUNDRAS. THE BODY OF MY VEHICLE HAS NO RUST ANYWHERE, AND THE MILEAGE IS EXTREMELY LOW. I CANNOT EVEN FIND A MECHANIC TO FIX IT, BECAUSE THE FRAME IS SO BAD. I WAS TOLD, IF IT GETS FIXED, ANOTHER PART OF THE FRAME MAY FAIL WHEN I'M CRUISING ON THE HIGHWAY AND PEOPLE COULD GET HURT OR KILLED. NO MECHANIC WANTS THIS LIABILITY IN DOING A REPAIR.

NHTSA ID

10731909

Incident

Jun 30, 2015

Mileage

72,000 mi

DRIVING DOWN THE LOCAL HIGHWAY, SMELLED TRANSMISSION FLUID BURNING. PULLED OVER TO FIND TRANSMISSION FLUID LEAKING FROM UNDER THE RADIATOR AREA. I WAS NEAR THE GARAGE THAT WORKS ON THE VEHICLE AND WAS ABLE TO DRIVE THERE. SKID PLATE WAS REMOVED AND THE TRANSMISSION LINES THAT RUN ALONG THE RADIATOR SUPPORT FRAME RUSTED THROUGH. THE MECHANIC SERVICING THE VEHICLE SAID I WAS LUCKY, THAT THIS COULD HAVE CAUSED TRANSMISSION FAILURE AND OR FIRE IN THE ENGINE COMPARTMENT WHILE DRIVING. TOYOTA DEALER WAS CONTACTED, SAID, THIS WAS A COMMON PROBLEM WITH THESE VEHICLES, BUT NO RECALL OR NOTIFICATIONS SENT THE OWNERS TO INSPECT THIS ITEM FOR RUST THROUGH. WHEN THIS PROBLEM WAS FOUND, THE FRAME UNDER THE RADIATOR WAS FOUND TO BE RUSTED THROUGH ALSO. ( LISTED IN ANOTHER COMPLAINT.) *TR

NHTSA ID

10658731

Incident

Oct 6, 2014

Mileage

85,400 mi

FRONT SUPPORT FRAME UNDER RADIATOR RUSTED THROUGH. THE LOCAL TOYOTA DEALER TOLD ME THIS IS A COMMON PROBLEM AND THERE IS NO FIX. THE VEHICLE IS UNSAFE TO DRIVE AND THE QUESTION IS HOW WOULD THIS HOLD UP IN A FRONTAL CRASH. THE VEHICLE HAS A LITTLE OVER 85,000 MILES AND THIS HAPPENS. IT IS IN A AREA WHERE SALT IS USED. MANY OF THESE VEHICLES ARE ON THE ROAD, MANY LIKE ME WOULD NOT HAVE KNOWN OF A BROKEN FRAME UNLESS THE SKID PLATE WAS REMOVED.THERE WAS ALSO AN ISSUE WITH THE TRANSMISSION LINES RUNNING ALONG THE FRAME LISTED IN ANOTHER COMPLAINT. *TR

NHTSA ID

10658726

Incident

Oct 6, 2014

Mileage

85,400 mi

I OPENED THE PASSENGER SIDE DOOR TO PLACE MY BAG DOWN. THE CAR ROLLED OUT OF GEAR DOWN MY DRIVEWAY WITH MY DAUGHTER IN THE FRONT SEAT. THEN I HAD TO JUMP INTO THE ROLLING CAR TO PUT IT BACK INTO PARK AND THE KEYS WERE NOT IN THE IGNITION. *TR

NHTSA ID

10503306

Incident

Mar 16, 2013

DRIVE SHAFT IS CLANGING, BANGING, CAUSING SLAMMING WITH THE BRAKING ACTION SURGING FORWARD SEVERAL FEET BEFORE STOPPING. *TR

NHTSA ID

10460358

Incident

Jun 2, 2012

Mileage

56,000 mi

TL* THE CONTACT OWNS A 2004 TOYOTA 4-RUNNER. WHILE DRIVING APPROXIMATELY 15 MPH, THE CONTACT ATTEMPTED TO ENGAGE THE 4-WHEEL DRIVE BUT IT WOULD NOT ENGAGE. THE VEHICLE WAS BROUGHT TO A STOP AND SHE THEN ATTEMPTED TO ENGAGE THE 4-WHEEL DRIVE AGAIN BUT TO NO AVAIL. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER WHERE SHE WAS ADVISED THAT THE TRANSFER HOSE WAS FRACTURED AND BOTH REAR AXLES WERE LEAKING. THE FAILURE WOULD ONLY OCCUR WHEN ATTEMPTING TO ENGAGE THE 4-WHEEL DRIVE. THE VEHICLE HAD NOT BEEN REPAIRED. THE APPROXIMATE FAILURE MILEAGE WAS 112,000 AND THE CURRENT MILEAGE WAS 113,000. UPDATED 1/5/12*CN

NHTSA ID

10386703

Incident

Feb 1, 2011

Mileage

112,000 mi

FOUR MONTHS AGO I PURCHASED A 2004 TOYOTA 4RUNNER LIMITED WITH APPROX. 82,000 MILES. A MONTH OR SO LATER, I APPROACHED A STOP SIGN AND AS I BRAKED, THE VEHICLE SUDDENLY ACCELERATED. I STEPPED AS HARD AS I COULD ON THE BRAKE AND FORTUNATELY, THE VEHICLE STOPPED. AT THE TIME, I WAS SCARED BUT THOUGHT THAT MAYBE BY MISTAKE, MY FOOT WAS SPANNING BOTH PEDALS (I DIDN'T THINK SO BUT COULDN'T BE 100% POSITIVE). YESTERDAY, I APPROACHED ANOTHER INTERSECTION WITH MY FOOT CLEARLY ON THE BRAKE PEDAL AS I WAS COMING TO A CONTROLLED STOP WHEN, SUDDENLY, THE VEHICLE ACCELERATED AGGRESSIVELY. AGAIN, I WAS ABLE TO SLOW THE VEHICLE DOWN BY ALMOST STANDING ON THE BRAKE PEDAL, THOUGH NOT ENOUGH TO STOP ME FROM GOING THROUGH THE INTERSECTION WITHOUT STOPPING. THIS TIME THERE WAS NO DOUBT - THE VEHICLE ACCELERATED ON ITS OWN. THE PEDAL DID NOT STICK AS MY FOOT WAS ON THE BRAKE AS I WAS COASTING TO A STOP. THIS VEHICLE DEFINITELY HAS A DEFECT AND IT WAS VERY SCARY. MY WIFE WILL NOT DRIVE THIS CAR AND I ONLY WILL NOW IF I ABSOLUTELY HAVE TO. *TR

NHTSA ID

10310253

Incident

Feb 12, 2010

Mileage

83,000 mi

1. THERE IS A SERIOUS "CLUNK" NOISE WHEN TAKING MY FOOT OFF THE BRAKE FROM A STOP. 2. MY VEHICLE MAKES A LOUD NOISE WHEN STOPPED AT AN INTERSECTION COMBINED WITH A SURGING FORWARD AS IF BEING REAR ENDED. 3. WHEN APPLYING THE BRAKES, AFTER IT HAS BEEN SITTING FOR A NUMBER OF HOURS, IT SHAKES AND BANGS EXTREMELY VIOLENTLY. *TR

NHTSA ID

10217737

Incident

Feb 11, 2008

Mileage

2,000 mi

1.) THERE IS A SERIOUS "CLUNK" NOISE WHEN BRAKING AND ALSO THE SAME NOISE WHEN STARTING FROM A COMPLETE STOP WHEN YOU TAKE FOOT OFF BRAKE. 2.) THERE IS "SULFUR SMELL " IN CABIN FROM CATALYTIC CONVERTER. *TR

NHTSA ID

10209988

Incident

Sep 1, 2007

Mileage

55,000 mi

I HAVE A 2004 LIMITED 4RUNNER TOYOTA, ALL WHEEL DRIVE, WITH V8. AFTER ABOUT 20 THOUSAND MILES, MY VEHICLE BEGAN MAKING A VERY LOUD NOISE WHEN COMING TO A STOP, WHILE SIMULTANEOUSLY SURGING FORWARD LIKE I WAS REAR ENDED. THIS NOISE ALSO HAS A DISTINCT METALLIC SOUND AND JARRING VIBRATION EACH AND EVERY TIME. IF THE BRAKE IS NOT PRESSES FIRMLY, THE CAR WILL LOUNGE FORWARD. THIS NOISE AND "CLANKING" ALSO OCCURS WHEN LIFTING MY FOOT OFF OF THE BRAKE WHEN THE CAR WAS STOPPED AND NOT IN NEUTRAL. I FIRST REPORTED THIS PROBLEM TO TOYOTA ABOUT A YEAR AGO AND THEY SAID THAT IT WAS A LUBRICATION AND MAINTENANCE ISSUE. THE TRIED TO CHARGE ME 500 DOLLARS FOR A FOUR-WHEEL DRIVE SERVICE. WHEN I PROTESTED THAT THIS WAS NOT IN THE MANUAL, THEY ADMITTED THAT THEY LUBRICATED THE PROPELLER SHAFT AND THAT THEY WOULDN'T CHARGE THIS TIME. TOYOTA INVOICE # W55722. WELL, THAT ELIMINATED ABOUT 90 PERCENT OF THE PROBLEM, BUT THE "CLANK" CAME BACK IN ABOUT A MONTH. I HAVE RECENTLY READ THAT ALL LIMITED EDITION 4RUNNERS FROM 03-06 HAVE THIS CLANKING PROBLEM, IN ADDITION TO THE LEXUS GX-470, THAT SHARES THE SAME DRIVESHAFT. HOWEVER, LEXUS IS FIXING THE PROBLEM WHILE TOYOTA IS PLAYING STUPID AND SAYING THAT IT IS NORMAL. CAN YOU PLEASE FORCE TOYOTA TO FIX MY VEHICLE IN THE SAME MANNER THAT LEXUS IS? PLEASE SEE THIS INTERNET LINK TO UNDERSTAND THAT THIS IS A SERIOUS PROBLEM: HTTP://WWW.TUNDRASOLUTIONS.COM/FORUMS/4RUNNER/53302-4RUNNER-V8-CLUNK-IN-DRIVETRAIN/. *JB

NHTSA ID

10205151

Incident

Oct 7, 2006

Mileage

13,000 mi

VIBRATION ABOVE 70 MPH, FELT THROUGH STEERING WHEEL, PEDAL AND FLOORBOARD. *JB

NHTSA ID

10098053

Incident

Jul 19, 2004

Mileage

10,500 mi

PURCHASED A 2004 TOYOTA 4 RUNNER. NOTICED "WOBBLE" OR "VIBRATIONS" IN STEERING WHEEL WHEN ACCELERATING AND AT SPEEDS AROUND 70-75 MPH. TOOK IN FOR MAINTENANCE, TECHNICIAN BALANCED TIRES. STILL HAD PROBLEM SO TOOK IT BACK IN RESULTING IN A ROAD FORCE BALANCE AND NEW SET OF TIRES. STILL HAVE MILD VIBRATION. *JB

NHTSA ID

10066425

Incident

Mar 24, 2004

2004 SR5 V6 4WD EXPERIENCES DRONING VIBRATION OR RUMBLING ON FLOOR, PEDALS, AND STEERING WHEEL WHEN CAR IS DRIVEN BETWEEN 1500-2000 RPM. VIBRATIONS ARE SIGNIFICANTLY WORSE FOR AMBIENT TEMPERATURES BELOW 35 DEGREES F. AND VERY BAD BELOW 15 DEGREES F. ALSO BECOMES MORE PREDOMINANT DURING ACCELERATION. VIBRATION DISSAPPEARS WHEN TRANSMISSION IS SHIFTED INTO NEUTRAL AT SAME SPEED. APPEARS PROBLEM IS IN DRIVE TRAIN/TRANSAXEL AND NOT TRANSMISSION. *AK

NHTSA ID

10062559

Incident

Dec 23, 2003

Mileage

1,400 mi

WHILE DRIVING VIBRATION CAME FROM THE DRIVETRAIN/FRONT DIFFERENTIAL AT VARIOUS SPEEDS. SEEMED TO BE RELATED TO RPM AND OUTSIDE TEMPERATURE. MOST PROMINENT AT @2000 RPMS, AND BELOW 50 DEGREES. VIBRATION FELT IN PEDALS, FLOOR AND STEERING. HEARD THROUGHOUT THE VEHICLE. DEALER TECH TRYING, BUT NO ANSWERS. *AK

NHTSA ID

10058619

Incident

Jan 10, 2004

Mileage

100 mi