2004 Toyota 4Runner Steering Problems

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

I have taken my car to Mountain states Toyota as well as corwin toyota for a tripped light it has to do with vehicle stability system it trips leaving the vehicle stability option not usable. I have told both dealers not to just reset the code however this is what’s happening and they don’t seem to know why it’s doing this. we have repaired the knock sensors and speed sensors. It feels unsafe driving when this trips when road conditions call for all wheel drive. the technician can’t figure it out why. their only solution is to keep resetting. This is not the option I want I need it repaired and they don’t seem to want to do it or figure out and give us options on repair.

NHTSA ID

11556430

Incident

Nov 9, 2015

My 4 runner only has 147,000 miles and is a great running vehicle but my frame is rotted badly. I have large holes throughout, the front crossmember under radiator with tow hooks has completely rusted off, and now I found where my rear lower drag link bolts to frame is about to come off. I have had to repair rusty brake lines multiple times. My rear axle carrier just sheds large flakes of rust. I love this truck but now it is almost too dangerous to drive and with all the inflation lately I cannot afford another vehicle.

NHTSA ID

11457720

Incident

Mar 21, 2022

Rear section of the frame snapped in half during normal driving. Barely driveable extremely hazardous and will remained parked.

NHTSA ID

11444931

Incident

Dec 25, 2021

My steering became very loose with a lot of movement in the steering wheel. The universal joint in the steering column shaft was bad. Upon further investigation, both lower control arms on the front wheels were rusted through, (from the inside out), with one of them bent because of the lack of metal support that rusted away, which caused my wheels to be misaligned and hard to control. Upon additional inspection, the frame has rusted out in multiple places which could allow it to break in half. (pictures of one portion of the frame are attached.) I have had the steering column and lower control arms replaced but multiple body and frame shops state the frame is rusted too much to repair. I know Toyota recalled several models for frame rust issues but have not included the 4Runner, which I cannot understand. This rust has been noticed for several years on my vehicle with attempts to keep it clean and rust free. However, the rusting process is occurring from the inside of the frame toward the outside, so you can't tell how bad it really is until you see the holes protruding through the frame. This model should be included in a class action suit requiring Toyota to compensate the owners for this defect and removing these models from service to avoid potential accidents and casualties caused by inferior iron products that were used in their manufacture.

NHTSA ID

11436010

Incident

Sep 13, 2021

SEVERE FRAME RUST ON 2004 4RUNNER SR5 SPORT. SUSPENSION RUST, STEERING COMPONENTS RUST. HOLES IN VEHICLE FRAME DUE TO RUST. I WENT TO TWO MECHANICS THAT TOLD ME THAT THIS RUST WAS BEYOND REASONABLE FOR NORMAL RUST ON FRAME, THEY BOTH STATED IT MAY BECOME DANGEROUS AND TO CONTACT TOYOTA DIRECTLY. THE VEHICLE IS BECOMING DANGEROUS TO DRIVE DUE TO POSSIBLY OF FAILING COMPONENTS AND OR FRAME.

NHTSA ID

11363977

Incident

Oct 12, 2020

PICTURES SHOW SIGNIFICANT RUST DAMAGE ON THE RIGHT BACK FRAME NEAR THE MUFFLER. DEALERSHIP STATED IT WOULD COST $14,000 TO REPLACE THE FRAME OF THE VEHICLE. CURRENTLY THE CAR HAS 125,000 MILES. VIN UNKNOWN *LN*JB

NHTSA ID

11282913

Incident

Nov 27, 2019

Mileage

125,000 mi

SINCE BUYING MY FORERUNNER USED IN 2015 I HAVE ONLY BROUGHT IT TO THE DEALERSHIP FOR MAINTENANCE BED INSPECTIONS WITH TOYOTA PROFESSIONAL MECHANICS. UPON BRINGING MY VEHICLE IN FOR A ROUTINE OIL CHANGE AND INSPECTION I WAS TOLD THAT THE FRAME IS RUSTED OUT AND UNSAFE TO DRIVE. I WAS SHOCKED AND UPSET AS I'VE ONLY USED A TRUSTED TOYOTA PROFESSIONAL MECHANICS AND SOMEHOW THEY SEEM TO HAVE OVERLOOKED A FRAME THAT WAS COMPLETELY RUSTING OUT AND THEREFORE PUTTING MY LIFE AND MY CHILDREN'S LIVES IN HARMS WAY. I CONTACTED TOYOTA HEADQUARTERS TO NO AVAIL, THEY CLAIMED THERE'S NOTHING THEY CAN DO AS THERE ARE NO RECALLS. HOWEVER I FEEL THEY ARE RESPONSIBLE FOR THEIR PROFESSIONAL MECHANICS OVERLOOKING SUCH A SERIOUS ISSUE BUT YET HAVING NO PROBLEM WITH ME CONTINUING TO PUT MONEY INTO THIS VEHICLE AS I PLANNED ON OWNING IT FOR QUITE SOME TIME. AFTER THE FRAME RUST WAS POINTED OUT MY STEERING THEN SEPARATED FROM THE SUSPENSION WHILE DRIVING HOME BEING A SINGLE MOTHER AND HAVING ONLY ONE VEHICLE I HAD NO CHOICE BUT TO TRY TO DRIVE IT I AM EXTREMELY UPSET AND THIS IS COMPLETELY UNACCEPTABLE

NHTSA ID

11174353

Incident

Aug 18, 2018

Mileage

215,117 mi

EXCESSIVE RUST IS COMPROMISING STEERING CONTROL.

NHTSA ID

11163086

Incident

Dec 10, 2018

Mileage

250,000 mi

SINCE VEHICLE WAS 5YRS OLD THE FRAME HAS RUSTED TERRIBLY. THE RUST IS SO SIGNIFICANT THERE ARE HOLES AND PIECES OF IT HAVE JUST FALLEN OFF. CURRENTLY, THE STEERING JOINT IS SO RUSTED THAT IT CANNOT BE DRIVEN SAFELY BECAUSE IT FEELS LIKE IT MAY LOSE CONTROL ON THE ROAD. ENTIRE UNDERCARRIAGE APPEARS SO BADLY RUSTED THAT I AM NOT SURE THIS VEHICLE IS SAFE TO DRIVE ANYMORE.

NHTSA ID

11140298

Incident

Aug 31, 2018

Mileage

131,000 mi

TOYOTA TRUCK FRAME CORROSION UPON INSTALLATION OF FAILED SUSPENSION COMPONENTS ON MY 2004 TOYOTA 4RUNNER, MY INDEPENDENT MECHANIC INFORMED ME OF SUBSTANTIAL FRAME CORROSION. I CONTACTED LYNCH TOYOTA WITH MY CONCERNS, LYNCH TOYOTA INSPECTED MY 4RUNNER AND FOUND SUBSTANTIAL FRAME CORROSION, VEHICLE DEEMED UNSAFE, AND SHOULD NOT BE DRIVEN IN ANY CAPACITY, FRAME REPLACEMENT RECOMMENDED BY LYNCH TOYOTA IN MANCHESTER CONNECTICUT. THE STEERING SHAFT IS FROZEN AND BINDING DUE TO CORROSION. THE SUSPENSION COMPONENTS ARE IN JEOPARDY OF BREAKING AWAY FROM CORRODING FRAME. TOYOTA REFUSES TO INCLUDE VEHICLE IN FRAME REPLACEMENT PROGRAM OFFERED TO ALL OTHER BODY ON FRAME CONSTRUCTED TRUCKS. 4RUNNER FRAMES ARE FAILING IN THE SAME WAY AS TACOMA, SEQUOIA AND TUNDRA, YET TOYOTA CLAIMS THAT NO PROGRAM IS IN PLACE TO ASSIST YOU, SORRY FOR YOUR TROUBLES WAS TOYOTA'S RESPONSE WHEN CONTACTED BY PHONE ON TWO OCCASIONS POST INSPECTION OF MY 4RUNNER BY LYNCH TOYOTA.

NHTSA ID

11131907

Incident

Aug 31, 2018

Mileage

128,672 mi

WHILE DRIVING ON THE HIGHWAY MY CAR WENT OUT OF ALIGNMENT DUE TO A ROTTEN TORSION BAR MOUNT. THE ENTIRE FRAME ALSO HAS LOTS OF ROT

NHTSA ID

11128186

Incident

Jul 5, 2018

Mileage

151,000 mi

MY 2004 TOYOTA 4 RUNNER IS IN THE DEALER FOR ROUTINE MAINTENANCE. MOST OF THE CAR MAINTENANCE HAVE BEEN AT THIS LOCAL TOYOTA DEALERSHIP. I JUST HAD THE CV BOOTS AND SWAY BAR BUSHINGS REPLACED THIS PAST SPRING AND SUMMER. I HAVE THE RECORDS FOR THESE PARTICULAR MAINTENANCE AND REPAIR. MY SERVICE MECHANIC MENTIONED THERE IS SIGNIFICANT AMOUNT OF RUST ON THE FRAME/ CHASSIS. ON SEPTEMBER 7, THE MECHANIC AT THE SAME DEALERSHIP SHOWED ME AGAIN THE EXCESSIVE RUST ON THE FRAME. IT IS SO SEVERE, ONE OF THE LOOPS FOR TOWING THE TRUCK IN THE FRONT OF THE FRAME JUST BROKE OFF. I ATTACHED THE PICTURE OF THE BROKEN HOOK/LOOP IN THIS DOCUMENT. THE TRUCK HAS 102,000 MILES ON IT. IT IS MOSTLY IN THE GARAGE IF NOT BEING USED. I UNDERSTAND THAT OTHER MODELS IN THE SAME YEARS LIKE THE TOYOTA TACOMA & TOYOTA SEQOIUA HAVE THE SAME EXCESSIVE RUST BUT THERE IS AN ALREADY RECALL PROGRAM FOR THESE MODELS. DO THE 4 RUNNER FROM THE SAME YEARS HAVE THE SAME FRAMES. WHY IS THERE NO RECALL FOR THE 4 RUNNER FOR THE EXCESSIVE RUST ISSSUE WHICH CAN BE A SAFETY PROBLEM FOR THE DRIVER AND THE PASSENGERS? THE MECHANIC DOES NOT RECCOMEND ME DRIVING THIS CAR DUE TO THE EXCESSIVE RUST. THE MECHANIC WARNED ME THAT RUST IS SO EXCESSIVE THAT MY RADIATOR CAN JUST FALL OFF BECAUSE THE PART OF THE FRAME HOLDING IT IN PLACE IS SO CORRODED FROM RUST. I AM HOPING TOYOTA CAN ADDRESS THIS ISSUE SOONER THAN LATER. IT IS A SAFETY ISSUE.

NHTSA ID

11128096

Incident

Sep 7, 2018

Mileage

102,000 mi

FRAME AND REAR AXLE HOUSING RUST - CAUSED THE UPPER CONTROL ARMS, WHICH PREVENT ROTATION OF THE REAR AXEL, TO DISCONNECT FROM THE HOUSING/FRAME. ALSO, STEERING HAS BECOME STIFF AND BUMPY AS YOU TURN THE WHEEL. THIS MAY BE DUE TO FRONT CROSSMEMBER RUST OR RUST ON THE STEERING UNIVERSAL JOINT.

NHTSA ID

11001548

Incident

Jan 1, 2017

POWER STEERING IS HARD WHEN YOU ARE MAKING TURNS

NHTSA ID

11000570

Incident

Jun 1, 2017

Mileage

162,000 mi

THE U-JOINT IN MY YEAR, AND MANY OTHER YEARS CLOSE TO THE SAME PERIOD, RUSTS OUT IN THE BEARINGS AND REQUIRES REPLACEMENT. THIS MAKES THE STEERING SIGNIFICANTLY DIFFICULT. HERE IS JUST ONE, OF MANY, WEBSITES DEDICATED TO THIS PROBLEM. I AM HAVING MINE FIXED NEXT WEEK BUT THE GENERAL CONSENSUS IS THAT THIS IS A MAJOR FAULT OF TOYOTA AND IT SHOULD BE RECALLED, HERE IS THE WEBSITE: HTTP://WWW.TOYOTA-4RUNNER.ORG/4TH-GEN-T4RS/87941-COMMON-STEERING-PROBLEM.HTML THANKS, DAN

NHTSA ID

10983810

Incident

Apr 1, 2017

Mileage

175,000 mi

WHEN VEHICLE IS DRIVEN OVER A ROUGH ROAD THERE IS A RATTLE SOUND COMING FROM STEERING COLUMN..NO RATTLE ON SMOOTH ROADS LIKE HIGHWAYS.......ITS BEEN DOING THIS FOR A LONG TIME,YRS....SEEMS LIKE SOMETHING IS LOOSE IN STEERING COLUMN

NHTSA ID

10837297

Incident

Dec 13, 2015

Mileage

195,435 mi

BOUGHT 4TH GENERATION 4RUNNER IN 1-15 FROM DEALER AFTER OWNING 4 PRIOR 3RD GENERATION ONES AND THIS ONE IS PLAGUED WITH EXCESSIVE RUST BEYOND NORMAL WEAR IN FRAME (SOME HOLES), SUSPENSION, STEERING RACK AND SHAFT, BRAKE COMPONENTS, VIRTUALLY EVERYTHING STEEL UNDER THE BODY HAS RUSTED EXCESSIVELY WHILE BODY REMAINS RUST FREE. I KNOW 95-03 TACOMAS AND TUNDRAS WERE UNDER FRAME AND BRAKE LINE RECALL DUE TO SAME ISSUE BUT FROM THE HUGE NUMBER OF POSTINGS ON INTERNET OF PROBLEM BEING JUST AS BAD IF NOT WORSE IN 3RD AND 4TH GENERATION 4RUNNER. YES THE FRAMES WERE A DIFFERENT STYLE BUT THE FRAMES IN THESE 4RUNNERS ARE EVEN WORSE AS PROBLEMS WITH RUST DUE TO DESIGN ARE EATING THEIR WAY FROM INSIDE OUT MAKING IT MORE OF A SILENT KILLER AS IT GOES UNNOTICED UNTIL RUST BREACHES ALL THE WAY THRU FRAME AND BY THAT POINT IT IS NOT ONLY UNSAFE TO DRIVE, IT HAS BEEN UNSAFE TO DRIVE FOR A LONG TIME BEFORE GETTING TO THAT POINT. THIS IS MAJOR PROBLEM AS NOTED IN 1000'S IF NOT MORE NOTED CASES ON INTERNET FORUMS AND TOYOTA REFUSES TO TAKE RESPONSIBILITY LEAVING ALL THESE PEOPLE STUCK WITH THEM AND THEIR FAMILIES AND KIDS THAT THEY PUT IN THESE POTENTIAL DEATH TRAPS AT RISK OF FRAME, BRAKE, STEERING, SUSPENSION FAILURES THAT COULD RESULT IN LOSS OF VEHICLE CONTROL, ACCIDENTS, AND DEATHS. I'VE CLEANED, SPRAYED RUST PREVENTATIVE OILS AND PAINTS ON AREAS OF CONCERN AND RUST MAKES ITS WAY BACK THRU IN WEEKS TIME. THE MANY OF OWNERS WITH THIS ISSUE ARE STUCK WITHOUT RESOURCES TO BUY ANOTHER DAILY DRIVER AND HAVE NO CHOICE BUT TO TAKE CHANCE WITH THE UNCERTAINTY OF POTENTIAL FAILURE AT ANYTIME. TOYOTA IS AWARE AND OBVIOUSLY KNEW THEY HAD RUST ISSUE WITH OTHER MODEL YEARS BUT THEY KNOW THEY HAVE SAME ISSUES WITH NEWER MODELS NOT INCLUDED ON ORIGINAL FRAME RUST RECALL AND ITS TIME THEY ARE FORCED TO STEP UP AND TAKE RESPONSIBILITY FOR THE FAULTY FRAMES AND UNDERBODY STEEL COMPONENTS.

NHTSA ID

10836938

Incident

Jan 30, 2015

Mileage

152,000 mi

SUV IS UNSAFE TO DRIVE DUE TO EXCESSIVE RUSTING OF FRAME AND ALL OTHER UNDERCARRIAGE METAL PARTS. FRAME INTEGRITY IS SERIOUSLY COMPROMISED. RUST IS EXPONENTIATING OVER TIME. RUST LEACHING TO OTHER MAJORS PARTS LIKE THE EXHAUST. TRANSMISSION, RADIATOR, AC, WHEELS, BRAKES, EXHAUST, STEERING, ETC ALL ARE COMPROMISED AND FAILING DUE TO RUST. THIS HAS BEEN GOING ON FOR YEARS. RADIATOR REPLACED. AC LEAKING. OCT 2011 HEAT SHIELD RUST NOTED BY TOYOTA. FEB. 2014 HEAT SHIELDS WERE REMOVED BY TOYOTA. THEY CLAIMED THAT THE TRUCK DOESN'T NEED THE HEAT SHIELDS. THEY DID NOT MENTION THE FRAME RUSTING OR THE LIFETIME EXHAUST RUSTING. THEY DID NOT MENTION THAT THIS IS A COMMON ISSUE WITH 4RUNNERS. I HAVE ALWAYS HAD ISSUES WITH THAT SERVICE DEPT. BUT THE ONLY OTHER TOYOTA IS WORSE. THIS ISSUE NEEDS SERIOUS RECALL ASAP. I THINK THESE TRUCKS WILL START FAILING AND CAUSING DEATHS SOON. NUMEROUS ISSUES WITH THIS TRUCK OVER THE YEARS ALL MAY BE DUE TO RUST. BRAKES DON'T SEEM TO LAST AND THE TRUCK IS HARDLY USED. I BELIEVE RUST IS INTERFERING WITH THE BRAKES.

NHTSA ID

10764189

Incident

Oct 27, 2011

Mileage

98,007 mi

2004 TOYOTA 4RUNNER LIMITED, HAS EXCESSIVE CHASSIS RUST AND ROTTED OUT AT SOME POINT ON THE SUB FRAME, CONTACTED THE DEALER AND THERE IS NO RECALL AVAILABLE ALSO CALLED TOYOTA AND RECALL IS NOT AVAILABLE.I AM AFRAID THAT THE CHASSIS WILL BREAK AND CAUSE AN ACCIDENT.

NHTSA ID

10744741

Incident

Nov 10, 2011

Mileage

86,000 mi

FRONT CALIPER SEIZE UP L/F AND R/F 3 INCIDENTS 11/2012 02/2015 06/2015

NHTSA ID

10724056

Incident

Nov 1, 2012

Mileage

84,000 mi

MAJOR RUST ON FRAME AND OTHER MECHANICAL PARTS. NOT EXPOSED TO SALT DOES NOT OCCUR WITH MY OTHER VEHICLES. *TR

NHTSA ID

10503523

Incident

Dec 31, 2009

Mileage

80,000 mi

TL* THE CONTACT OWNS A 2004 TOYOTA 4 RUNNER. THE CONTACT WAS DRIVING 20 MPH WHEN THE STEERING WHEEL FAILED AND BECAME STIFF WITHOUT WARNING. THE CONTACT MENTIONED THAT THE DRIVER WAS ABLE TO REGAIN CONTROL OF THE VEHICLE AND BRING IT TO A STOP. THE VEHICLE WAS TOWED TO A LOCAL REPAIR SHOP WHERE IT WAS DIAGNOSED THAT THE LINKAGE TO THE STEERING KNUCKLE WAS FRACTURED AND AS A RESULT, THE STEERING KNUCKLE, STABILIZER BAR, STEERING LINKAGE, UPPER AND LOWER CONTROL ARMS, WHEEL AND BEARINGS, AND THE ROTORS WOULD NEED REPLACING. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE BUT DID NOT OFFER ANY ASSISTANCE. THE VEHICLE WAS REPAIRED. THE FAILURE MILEAGE WAS 65,000 AND THE CURRENT MILEAGE WAS 66,000.

NHTSA ID

10416668

Incident

Jun 10, 2011

Mileage

65,000 mi

2004 TOYOTA 4RUNNER. CONSUMER STATES THERE WAS A CLICKING NOISE COMING FROM THE STEERING WHEEL WHILE TURNING RIGHT OR LEFT *TGW THE NOISE WAS A FAINT CLICKING, INCREASING ONLY SLIGHTLY IN VOLUME OVER TIME. THE VEHICLE WAS TAKEN TO THE DEALER AND AN INSPECTION REVEALED THE INNER SHAFT SHOWED GROOVES WHERE THE BEARING RACE HAD CUT INTO THE STEERING SHAFT TO THE EXTENT WHERE IT COULD HAVE CAUSED COMPLETE STEERING LOCK-UP AT ANY TIME. THE CONSUMER WAS INFORMED THAT THE ENTIRE STEERING COLUMN NEEDED TO BE REPLACED. *JB

NHTSA ID

10383528

Incident

Feb 1, 2011

I HAVE A 2004 4 RUNNER I RECENTLY HAVE HAD A STEERING VIBRATION THAT IS MAKING ME CRAZY IT FLUTTERS AROUND 55 TO 65 I HAVE GONE TO DIFFERENT DEALERS AND INDEPENDENT SHOPS PLUS I HAVE DONE LOTS OF TESTING WITH NO LUCK ON A PERMANENT FIX I HAVE RESEARCHED THE INTERNET FOR 6 MONTHS SINCE THE PROBLEM REALLY STARTED THE ONLY THING I CAN FIND IS THIS TSB ST001R-05 050908 STEERING THAT RELATES TO MY PROBLEM I HAVE HAD 9 NEW SETS OF TIRES AND A SET OF NEW WHEELS AND ALL NEW SUSPENSION NO MATTER WHAT I DO I CAN NOT GET RID OF THE FLUTTER IT SOME TIMES PERFECTLY SMOOTH EVEN OVER BUMPS SOMETIMES IT IS WOBBLING ALL OVER I HAVE ALREADY ENCOUNTERED A COLLISION DUE TO THIS ISSUE IT WAS JUST A FENDER BENDER NO MAJOR DAMAGE BUT THE ONLY THING LEFT FOR ME TO DO IS FIND OUT MORE ON THIS TSB I DISCOVERED I REALLY LIKE MY 4 RUNNER BUT I CANT HAVE THIS DEATH TRAP PUTTING PEOPLE IN JEOPARDY PLEASE HELP WITH ANY INFO THANKS. *TR

NHTSA ID

10293169

Incident

Oct 18, 2009

Mileage

65,237 mi