2004 Toyota 4RUNNER: ball joint or control arm failure

Filed Oct 20, 2022 · Body, Suspension · FL

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.

Filed May 22, 2022 · MI

The right rear control arm mount completely rusted away from the frame. Causing it to start fish-tailing out of control. Also there are other mounts that have rusted through. Like for instance, the gas tank strap mounted to the frame. There are also more areas of the frame that are rusting through. I'm just glad that I was the only one in the vehicle and going slow enough to not cause an accident. I then took it to an auto repair shop and they informed me that the frame on my vehicle has many problem areas of being rusted through. I have attached some photos of the problem areas taken from the repair shop.

Filed Oct 8, 2021 · Steering, Suspension · KY

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.

Filed Sep 2, 2021 · Suspension · WV

The control arms rusted completely off the frame. The whole frame has rust holes!

Filed Mar 2, 2021 · Body · MA

I purchased this vehicle in 2015 with 111k miles on it. Just found out today march 2 that the frame is shot and the control arms for the rear axle have let go on both sides do to frame rot, there are also other questionable parts of the frame. So very disappointed in this toyota vehicle. This car couldn't even last 20 years, not the reputation of what I thought toyotas were know for.

Filed Jan 25, 2021 · NH

My vehicle has severe frame rot, all of which coming from the factory welds to the surface points along with it's rotting from the inside out especially around the front lower control arm areas of the driver and passenger sides of the vehicle. This also reaching the back of the vehicles frame too.

Filed Dec 16, 2020 · Body · 159,000 miles · VA

My 2004 4runner limited v6 has significant rust build up on the frame, control arms, driveshaft, etc. I am the second owner with just over 21k miles driven in the past three year and right at 160k total. I've made sure to get regular washes to protect the undercarriage after inclement weather since I've owned the vehicle. After returning from a 10-month deployment, two shops have told me the condition is dangerous and requires significant replacement parts and anti-corrosion treatment to remedy the problem. I don't have thousands of dollars to spend on a truck that should last me at 250k miles. I will not let my wife and girls ride in this vehicle, but we need two cars. Imagine my shock to find out many other toyota owners have dealt with the same thing. This is clearly not a coincidence. Hoping for toyota to rectify this serious safety/quality issue.

Filed Oct 13, 2020 · Body · 155,000 miles · SD

Frame has sever rust-through and corrosion on the passenger side in front of the rear trailing link mount and behind the front control arm mount. Vehicle is driven in an environment where road salt is used in the winter, but this is excessive compared to other older vehicles. Vehicle is washed regularly in the winter.

Filed Apr 9, 2019 · Suspension · 150,000 miles · RI

Frame and suspension rust has weakened the parts to the point of failure. Rear upper control arm mounting bracket on rear axle broke while driving on highway while going around a turn. Vehicle's rear wobbled back and forth violently. I almost lost control of the vehicle. There are other pieces that look close to failure.

Filed Apr 9, 2019 · Body · 175,000 miles · NY

Toyota frame rusting. The frame on my 4runner is rusted to the point where I feel it is unsafe. The welds that hold the rear control arms are rusted completely through. When looking at the frame rail you can see daylight through the welds. There are other spots on the frame rails that are rusted just as badly I'm not able to get pictures off

Filed Mar 10, 2019 · 140,000 miles · MA

A thin metal support plate welded to rear axle connects upper control arms to rear axle. Both support plates totally disintegrated from rust. These plates are a structural component of vehicle suspension system. When the upper control arms failed from failed support plates, the brake warning light came on. The brake line had been damaged most lightly from brake line being hit by control arm. The motion/loud noise of detached control arms contacting metal axle was followed by brake light coming on. Within 2 years of purchase of automobile chassis rust was noticeable and commented by mechanics. When confronting toyota, their same comment of not being under wauranty prevailed. The last time I contacted them I asked to speak to their engineers because I felt the support plate design is unsafe and to thicken the plate would be a small expense. The vehicle was in motion when the support plates fractured. They told me I could talk to anyone else other than their support line and that the plate would not be changed. I am a degreed engineer with a bachelors and two masters in engineering and am disappointed in how they value pennies over an obvious safety issue. Best regards my name and phone are (xxxx) phone (xxxx) if you would like to discuss. Parts of this document have been redacted to protect personally identifiable information pursuant to the freedom of information act (foia), 5 u.s.c. 552(b)(6)

Filed Dec 16, 2018 · Body, Suspension · 145,000 miles · RI

My 16 year old daughter was driving on a city street and was turning into a driveway and the lower control arm on passenger side broke and I was told it was because the frame is rotted. Not sure if I am able to fix due to the frame. I am new to the northeast and was not aware of rotted frames out here.