2003 Toyota 4RUNNER: ball joint or control arm failure

Filed Sep 18, 2021 · Suspension · NE

I have not actually had an incident yet, but have been advised by the Toyota service team that I should no longer tow trailers and should consider not driving it at all due to frame rust/perforation in front of the rear control arms. This has been a well cared for vehicle that is in otherwise great shape (It has had every repair the dealership has ever recommended) the vehicle was bought per the dealerships claim that it could be driven "forever" as long as the dealership takes care of it. And now I'm faced with a massive expense to repair or replace the vehicle.

Filed Jun 20, 2021 · Body · NJ

The frame has rusted almost completely through near the front upper and lower control arms near the cross member there. The passenger side is so bad the welder I took it too sad he couldn’t repair it without doing the crossmember section and all. The driver side is not at bad but doesn’t look to hot. The crossmember where the radiator sits is also starting to completely rot away

Filed Apr 3, 2021 · Body · 127,000 miles · AL

Our 2003 4runner frame is rusted throughout. Not even safe to drive with 127,000 miles. The control arm is ready to fall off. Thankfully, a busted brake line got us into the shop before a bad accident happened. Now we're looking at spending $4000 on framework to make it safe to drive. So sad that this issue has been know for years and no one is making toyota make it right. Please do something before people get hurt. We were ready to take a 1000 mile trip from alabama to texas when we found out about the rust. My mechanic stuck a pencil through the frame! It's sooooo bad! Please do something!

Filed Feb 1, 2021 · Body, Suspension · 103,500 miles · PA

Rear driver side control arm broke off at the frame after striking pothole at highway speed. After the failure the vehicle was very hard to control and almost LED to a rollover. The vehicle was unable to be driven and had to be towed. Toyota recalled tundra's, tacoma's, and sequoia's for frame replacement so it is a known problem. Will toyota be held liable for accidents resulting from premature frame failure? By recalling the other models they obviously acknowledged it was a problem and 4runners share the same platform as the tacoma so why were they not included?

Filed Oct 14, 2020 · Body, Suspension · 140,000 miles · MN

The rust on the frame of this vehicle is unlike anything I've seen in comparison to it's age. I work on vehicles frequently and have not seen anything like this in a modern age vehicle, and vehicles that are over 40 years old that I own or work on don't have rust that is remotely this bad. Upon further investigation, I found the entire weld line of the frame rails to be corroded through in an approximately 28" section. With further investigation, the entire bottom section of that rail was rusted out to be extremely thin and separated at the seam, entirely compromising the integrity of the frame rail. 2 of the body mounts are also rusted out as well as some of the suspension mount components. The vehicle is at risk for having the spring and strut assembly or the control arm assembly detaching from the frame under normal operation conditions. This is an incredible safety risk as it could result in the vehicle losing all steering control. Luckily it was found before an accident occurred.

Filed Sep 17, 2020 · Body, Suspension · 200,000 miles · TN

Tl* the contact owns a 2003 toyota 4runner. The contact stated that the subframe was corroded causing both rear control arms to detach while driving. The contact inspected under the vehicle and noticed there were several spots covered with a black tape and painted over to conceal the rust and holes. The contact stated that the rear tire move forward and backward causing the tires to damage the bumper and the plastic trim panel. The vehicle was towed to the contact's residence. The contact called aaa and informed them of the failure and was informed to contact the federal safety agency. Neither the dealer nor the manufacturer were made aware of the failure. The failure mileage was approximately 200,000.

Filed Sep 11, 2020 · Body, Suspension · 160,000 miles · IN

The vehicle frame has multiple perforations greater than 10mm. One such perforation has created a crack on the frame just in front of the right rear lower control arm mount. If this vehicle were to hit a bad enough bump or pot hole, there exists a possibility the frame could snap and allow the control arm to become free and the vehicle would lose control

Filed Aug 29, 2019 · Engine, Suspension · 217,500 miles · IN

Tl* the contact owns a 2003 toyota 4runner. When the contact attempted to start the vehicle, it would not start. The contact mentioned that the head gasket needed to be removed and re-installed in order to start the vehicle. Also, while driving various speeds, the rear of the vehicle swayed uncontrollably to the left and right. The vehicle was taken to big o tires (2245 state st, new albany, in 47150, 812‑949‑0736) where it was diagnosed that the passenger side control arm was fractured and the driver's side control arm could fracture at any moment. The vehicle was towed to mccormick motor sports (1041 s 6th st, louisville, ky 40203, (502) 584-1981) where the contact was informed that the head gasket was causing cylinder three to misfire. The vehicle was not repaired. The manufacturer was made aware of the failure. The failure mileage was 217,500.

Filed May 17, 2019 · Brakes, Steering · 88,000 miles · IL · crash · 1 injury

The control arm separated from the rotted rusted frame while driving. Almost died!

Filed Dec 22, 2018 · Steering, Suspension · 104,000 miles · CT

Extreme rust/rot throughout my 2003 4runner frame. The body, interior, powertrain are 8.5 out of 10 the frame is a 0 I live in new england and recently purchased the 03 4runner sr5 based off it looks. I drove the 4runner of about a month before the incident happened. I was driving on a typical new england road, fairly smooth with pot holes here and there going approximately 45 m.p.h.. Without any warning the 4runner sent the front of the truck hard left and the rear of the truck to the right. The tires were screeching and I was sent sideways into oncoming traffic narrowing missing cars and pedestrians in the area. I got the truck to "crab walk" back across the road into a parking out and called a tow truck. When we got the truck home the tow truck driver and I took a look under the truck to see what went wrong. The right rear control arm mount had completely separated from the frame. With the truck on ththe ground I was able to roll the rear right wheel forward and backwards about 5 inches without the vehicle moving at all. I then got under the truck and saw that the cross member under the transmission had rusted away and and what not in contact with the driver side of the truck. Also I could push holes in the the frame with my fingers around the driver/ front passenger doors. I have not driven the 4runner since and I dont have 8k+ to pay a shop to replace a frame. Toyota needs to step up and take care of its customers before someone gets killed

Filed Nov 17, 2018 · Body, Brakes · 245,000 miles · NY

The frame on my SUV is very rusted and causing continuous problems. I've had to replace numerous parts underneath my car (sway bars, tie rods). Just the other night while driving home in a snow storm, I completely lost my brakes. Two of the main brake lines were completely corroded. A new frame would solve a lot of my problems. They've recalled tacomas and sequoias, wondering what the hold up is on the 4runner recall?

Filed Jan 20, 2016 · Body, Suspension · 104,000 miles · NY

Tl* the contact owns a 2003 toyota 4runner. While backing out of the driveway, the lower control arm failed and the vehicle became inoperable. The vehicle was towed to the dealer and an inspector sent by the manufacturer examined the damage. The inspector determined that the subframe bracket, which holds the lower control, had rusted and caused the lower control arm to fail. The inspector recommended that the entire frame of the vehicle be replaced. The manufacturer was notified of the failure. The failure mileage was 104,000.