2005 Toyota 4Runner Suspension Problems

I have a 2005 Toyota 4runner with frame rust that has caused everything under my 4runner to rust. Toyota knows these frames have problems with rust and corrosion and have done nothing, I am far from being the only one with this complaint or problem. It is up for inspection anytime. I have taken it to get work done at shops and been turned away because of the amount of rust on all bolts, lines, all metal under truck causing it to be a liability. I cant even get my skid plates off to fully address the issue. The metal is starting to split on the main frame by the tire, it is rotting from inside. Rust has always been there but last couple years has gotten really bad. So much rust my gas tank strap has broken but so much rust I cant get the skid plate off to fix it.

NHTSA ID

11737968

Incident

May 5, 2026

ENTIRE body frame has excessive rust, holes, and cracks. It is available for inspection. Toyota dealership says it is safe to drive for now but it is failing. I feel any cracks, rust, holes, separation of frame components places all occupants and anyone near the vehicle at risk for when anything fails - this could be when the vehicle is on the expressway in motion (such as when the GM ignition switch failures happened), causing catastrophic loss of life, injuries, and damage to all. It's not a matter of "if" it happens, it's "when" it will happen. There are no warning lamps, messages, or other symptoms of the problem. The exterior, interior, braking, engine of the vehicle are in remarkable shape so it's very misleading. There are also 4runners on dealership lots that have significant rust, holes, and cracks in the frames that the dealership does not warn about, rather, they still have high for-sale values because the vehicle looks good otherwise.

NHTSA ID

11663625

Incident

May 28, 2025

Excessive frame rusting. There are holes in the frame from rusting. At this point in time there isn’t anything I can do about the issues. Frame is unrepairable.

NHTSA ID

11562313

Incident

Dec 7, 2023

Frame of the vehicle is showing rust corrosion. The frame are the same as the tacomas that were released the same year. The tacomas were granted frame replacement by Toyota but 4Runners weren’t. Noticed a lot of other 4th generation 4Runners are having the same issues.

NHTSA ID

11553471

Incident

Nov 3, 2023

The contact owns a 2005 Toyota 4Runner. The contact stated while the vehicle was at the independent mechanic for servicing, and he was informed that the sub frame was severely corroded. The dealer was notified of the failure and referred the contact to the manufacturer. The manufacturer was notified of the failure and referred the contact to the NHTSA Hotline for assistance. The vehicle was not repaired. The failure mileage was approximately 166,000.

NHTSA ID

11520258

Incident

Apr 19, 2023

Mileage

166,000 mi

The frame on both sides of the vehicle in the front, where it connects under the radiator crossbar has rusted through.Not feeling to safe about this. also the transmission cooling lines are also looking thin. The dealership I have maint. done at informed me of this condition. Can send pictures if needed.

NHTSA ID

11484406

Incident

Mar 25, 2022

My frame has rotted through, causing the rear bump stops to fall off, putting excessive wear on both frame and suspension components. In parts of the frame, it has rotted all the way around and caused a loss in structural integrity. Worst of all, there is a hole near the rear most strap holding the gas tank to the chassis, which is a risk to not only me and my pregnant wife but others driving on the road around me if it where to fall off. Looking at the body, there is no rust or corrosion. The same goes for the engine bay, the rust is entirely located on the frame. Mechanically, the vehicle is in excellent shape. It has now got to the point it will no longer pass a NYS inspection.

NHTSA ID

11483876

Incident

Sep 1, 2022

Vehicle’s frame and suspension is showing major rust prematurely forming from the inside-out of the frame causing visible weakness in the structure of the frame that could cause engine or other suspension parts to fall off the frame of the car due to improper treatment of the frame. If I were to get in a car accident I don’t see the frame holding it’s structure. I would I highly suggest to have a safety recall done with frames with such damage.

NHTSA ID

11437140

Incident

Oct 18, 2021

Brought the car in for an alignment and I was told they couldn’t do it because of all the damage to the frame from rust, parts of the frame are not even there anymore, the front row hooks are gone, they said that all this damage ca impact the handle of the car and that it can’t be properly aligned and possibly won’t pass inspection.

NHTSA ID

11435632

Incident

Sep 22, 2021

Upon recent inspection of my vehicle, it was noted that the frame is severely corroded and rusted to the point where collapse or breaking of the frame is possible while driving. Apprently the frame was not properly treated for rust protection and can now be unsafe for driving. Enclosed are pictures of the rusted frame.

NHTSA ID

11431129

Incident

Aug 1, 2021

Frame and rear differential rust- extreme

NHTSA ID

11429160

Incident

Nov 9, 2018

The contact owns a 2005 Toyota 4Runner. The contact stated that while the vehicle was receiving maintenance work from an independent mechanic, the mechanic informed the contact that the sub frame was very rusted. The mechanic was unable to complete the maintenance work. The vehicle was taken to a dealer where they provided the contact an estimate for the repair. The vehicle was not repaired. The manufacturer was not notified of the failure. The approximate failure mileage was 142,500.

NHTSA ID

11427564

Incident

Jul 15, 2021

Mileage

142,500 mi

The contact owns a 2005 Toyota 4Runner. The contact stated that upon taking the vehicle to an independent mechanic, she was informed that significant corrosion had developed on the front end of the undercarriage. The contact was then referred by the independent mechanic to the dealer where she was informed that while was rust found on the undercarriage of the vehicle, the vehicle was safe to operate and no repairs were needed. A month after the dealer inspection, the contact stated that an abnormal sound was coming from her brake pedal upon depression without warning. Once the contact made it home, she had the vehicle towed to an independent mechanic. The mechanic initially informed her that the vehicle was a total loss however, he and another mechanic were able to remove a large portion of the rust and replaced the brake pads, rotors, power steering line, hose, and brake pads. Recently, contact stated that her son had driven the vehicle and that the vehicle began to exhibit the same brake failure that had been replaced by the mechanic. The manufacturer was notified of the failure but offered no assistance. The vehicle was not repaired. The failure mileage was approximately 93,000.

NHTSA ID

11425531

Incident

Aug 23, 2018

Mileage

93,000 mi

Extensive, rapidly spreading rust throughout the vehicle's frame and fuel tank supports leaving little or nothing holding the fuel tank or areas of the suspension together. Vehicle cannot be safely placed on a lift for service because of thin metal in the bottom of the frame. .

NHTSA ID

11423459

Incident

Jul 5, 2021

TL* THE CONTACT OWNS A 2005 TOYOTA 4RUNNER. THE CONTACT STATED THAT UPON TAKING THE VEHICLE TO A-1 TOYOTA (50 AMITY RD, NEW HAVEN, CT 06515) SIGNIFICANT RUST WAS DISCOVERED ON THE SUBFRAME OF THE VEHICLE. THE MECHANIC FOUND A HOLE IN THE RADIATOR SUPPORT AND ANOTHER HOLE ON THE DRIVER SIDE FRAME RAIL. THE CONTACT WAS INFORMED THAT THE VEHICLE WAS SAFE TO DRIVE HOWEVER, THE PROLONGED RUST BUILD UP COULD LEAD TO A SEVERE MECHANICAL FAILURE. THE CONTACT WAS INFORMED THAT THERE WERE NO RECALLS ON THE VIN. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE BUT OFFERED NO FURTHER ASSISTANCE. THE FAILURE MILEAGE WAS UNKNOWN.

NHTSA ID

11403514

Incident

Mar 1, 2011

UPON RECENTLY DRIVING A FAMILY MEMBER'S 2005 TOYOTA 4RUNNER LIMITED V8, I HEARD A KNOCKING NOISE COMING FROM THE FRONT OF THE VEHICLE OVER BUMPS. UPON INSPECTING THE VEHICLE, I DISCOVERED EXTENSIVE RUST ON NEARLY EVERY SINGLE PART OF THE STRUCTURAL FRAME, SUSPENSION COMPONENTS AND EVEN EXHAUST SYSTEM. SOME PARTS ARE SO BADLY RUSTED THAT THEY CAN BE PUNCTURED BY SIMPLY PUSHING YOUR FINGER THROUGH THEM (INCLUDING THE REAR FRAME CROSS MEMBER CRASH STRUCTURE BEHIND THE REAR BUMPER). THESE VEHICLES ARE RUSTING SO TERRIBLY THAT I'M SHOCKED NHTSA HASN'T FORCED TOYOTA TO RECALL THEM. YES, THEY'RE OLDER, BUT THE LEVEL OF RUST AND DECAY IS UNPRECEDENTED FOR NEARLY ANY MODERN CAR. TOYOTA ALREADY HAD TO RECALL ALL OF THEIR OTHER BODY-ON-FRAME VEHICLES (TACOMA, TUNDRA, SEQUOIA, AND LAND CRUISER) TO REPLACE THE FRAMES DUE TO RUST. WHY HAVE THEY NEGLECTED THE 4RUNNER WHEN IT'S ARGUABLY THE VEHICLE THAT WILL LIKELY SEE USE OFF ROAD MORE THAN ALL THE OTHERS? THE NHTSA SHOULD FORCE TOYOTA TO RECALL THESE CARS BEFORE SOMEONE IS KILLED. LOOK AT ANY ONLINE FORUM AS I DID LAST NIGHT AND YOU'LL SEE TOYOTA IS ACTUALLY BEING SUED IN A CLASS ACTION LAWSUIT FOR THIS VERY ISSUE. TONS OF PEOPLE ARE SHARING PHOTOS AND STORIES OF THEIR OWN INCIDENTS. SOMEONE IS GOING TO BE KILLED WHEN THEIR CAR DISINTEGRATES AS THEY DRIVE DOWN THE ROAD AND THEY LOSE CONTROL OF THEIR STEERING, BRAKING OR IF THEY'RE HIT IN A COLLISION AND THE STRUCTURAL MEMBERS OF THE CAR CRUMBLE LIKE A CRACKER.

NHTSA ID

11383217

Incident

Dec 12, 2020

Mileage

196,000 mi

THE FRAME UNDERNEATH THE FRONT BUMPER IS TOTALLY RUSTED AND CRUMBLING. MY MECHANIC SHOWED ME YESTERDAY AND SAID THE RADIATOR WOULD FALL OUT. ALSO THE CONTROL ARRMS TO THE FRONT TWO WHEELS ARE VERY BADLY RUSTED.

NHTSA ID

11376810

Incident

Nov 27, 2020

Mileage

172,934 mi

NOTHING HAPPENED YET BUT FOUND UPON CHECKING THAT THE REAR DIFFERENTIAL UPPER CONTROL ARM THAT IS ATTACHED TO THE FRAME IS RUSTED THROUGH. I AM AFRAID IT WILL DETACH WHILE DRIVING AND CAN CAUSE AN ACCIDENT. I HAVE REMOVED THE FLAKY METAL MYSELF IN THE SUMMER OF 2020 AND PAINTED IT TO AVOID FURTHER RUSTING. THE CROSSBAR IN THE FRONT THAT IS SUPPORTING THE RADIATOR IS RUSTED THROUGH AS WELL. THE METAL THAT IS HOLDING THE TANK IS GONE TOO.

NHTSA ID

11376362

Incident

Jun 14, 2020

Mileage

150,000 mi

FRAME IS RUSTED THRU ON BOTH FRONT SIDES WHERE THE CONTROL ARMS ATTACH

NHTSA ID

11363032

Incident

Oct 6, 2020

Mileage

230,000 mi

TL* THE CONTACT OWNS A 2005 TOYOTA 4RUNNER. THE CONTACT STATED THAT YEARS AGO, AN INDEPENDENT MECHANIC DISCOVERED SEVERE CORROSION ON THE UNDERCARRIAGE OF THE VEHICLE. THE CONTACT RECENTLY HAD A FUEL LEAK FAILURE WHICH SHE LINKED TO THE CORROSION ON THE VEHICLE. NEITHER THE DEALER NOR THE MANUFACTURER HAD BEEN NOTIFIED OF THE FAILURE. THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS UNKNOWN. *LN*JB

NHTSA ID

11354947

Incident

May 2, 2019

FRONT FRAME RUSTED BEYOND REPAIR.

NHTSA ID

11350092

Incident

Aug 18, 2020

Mileage

104,500 mi

THE FRAME IS RUSTING AWAY

NHTSA ID

11349832

Incident

Aug 13, 2020

I HAVE A 2005 TOYOTA 4RUNNER PURCHASED NEW GARAGED KEPT WITH 66200 MILES WITH EXCESSIVE FRAME AND UNDERBODY RUST. I AM CONCERNED WITHOUT A FRAME REPLACEMENT FROM TOYOTA I WILL NOT BE ABLE TO DRIVE IT AS THE SAFETY CRASH STANDARDS NOT TO BE ACCEPTABLE AS NEW OR FRAME TO BRAKE AND CAUSE AN ACCIDENT.

NHTSA ID

11339560

Incident

Apr 15, 2010

HI, I OWN A 2005 4RUNNER AND I AM CONCERNED ABOUT THE HEAVY AMOUNT OF RUSTING ON THE FRAME. THE FRAME IS RUSTY WHICH IS CAUSING HEAVY FLAKING OF THE AFFECTED MATERIAL. THE BODY OF THE VEHICLE IS PRISTINE BUT I FEAR THAT THE PREMATURE RUSTING OF THE FRAME WILL AFFECT THE ABILITY TO SAFELY DRIVE MY 4RUNNER IN THE FUTURE. I AM A SPECIAL EDUCATION TEACHER WITH TWO YOUNG DAUGHTERS AND DON'T HAVE THE INCOME TO GO OUT AND REPLACE THE FRAME OR BUY A NEW VEHICLE. THIS 4RUNNER IS THE ONLY VEHICLE I OWN AND IS MY DAILY DRIVER. MY STUDENTS AND THEIR GUARDIANS DEPEND ON ME TO ARRIVE SAFELY TO SCHOOL EVERYDAY SO THERE IS CONSISTENCY IN MY STUDENTS' LIVES. I HAVE SEEN MANY 4RUNNERS IN THIS AGE RANGE SUFFER FROM THIS SAME CORROSION. I AM CONCERNED THAT MY FAMILY WILL BE INJURED IN A MINOR ACCIDENT OR THE VEHICLE'S SAFETY MECHANISMS FAILING BECAUSE OF FRAME DAMAGE. I AM ALSO CONCERNED THAT I WILL LOSE MY ONLY MEANS OF TRANSPORTING MYSELF TO WORK. I AM A HUGE FAN OF TOYOTA, ESPECIALLY 4RUNNERS, AND WANT TO KEEP MINE AROUND FOR A LONG TIME. KEEPING TOYOTA VEHICLES AROUND FOR A LONG TIME IS WHAT THE COMPANY WAS BUILT UPON.

NHTSA ID

11321440

Incident

Feb 1, 2019

Mileage

140,000 mi

VEHICLE HAS VERY EXCESSIVE FRAME RUST. HOLES THROUGHOUT ENTIRE FRAME MAKING THE VEHICLE UNSAFE TO DRIVE. RUSTING FROM THE INSIDE OUT DUE TO NEGLIGENCE ON TOYOTAS PART. THIS VEHICLE HAS THE SAME EXACT FRAME THAT WAS RECALLED ON THE TACOMAS, TUNDRAS AND SEQUOIAS. PLEASE TELL ME WHY THE 4RUNNER WAS LEFT OUT?

NHTSA ID

11321132

Incident

Apr 12, 2020

Mileage

130,000 mi