Toyota 4RUNNER engine failure problems

Filed Aug 1, 2024 · Engine · SC

Make: Toyota Model: 4Runner Year: 2013 Mileage: 76,200 Description of Incident While driving on [XXX] at night, the vehicle experienced a sudden and catastrophic engine failure, leaving it immobilized in the middle of the highway. This presented an immediate and severe safety risk to both the vehicle occupants and other motorists. The failure was later determined to be caused by a malfunction in the Variable Valve Timing (VVT) oil control system, specifically an Exhaust Cam Gear failure. This led to a broken timing chain and subsequent engine failure. Inspection and Diagnosis The vehicle was inspected by an authorized Toyota Dealer in Florence, SC. They confirmed the failure of the oil control system and recommended a complete engine replacement, estimating costs over $5,000. Broader Implications and Potential Safety Hazard Further investigation, including consultations with multiple Toyota technicians, review of technical discussions on various platforms, and examination of online 4Runner forums, suggests that this issue is not isolated. Failures of the exhaust cam gear and problems with the VVT Oil Control System appear to be common in the Toyota 1GR-FE Engine and other engines equipped with this system. It's noteworthy that Toyota issued a voluntary recall in 2014 (Safety Recall 13V‑395, TM-TC-14021) for Lexus vehicles with similar issues. However, this recall does not appear to cover the 2013 1GR-FE 4Runner engine, despite the apparent similarity in potential failure modes. Safety Concerns This issue presents a significant safety hazard: Sudden engine failure at highway speeds can lead to loss of vehicle control. Unexpected vehicle immobilization, especially at night or in high-traffic areas, poses a severe collision risk. The apparent widespread nature of this issue suggests that many vehicles may be at risk of similar failures. Urgency for Action Given the severity of the potential outcomes and the ap INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

Filed Nov 25, 2021 · Brakes · VA

Seized front right brake caliper caused vehicle to slide off road during sudden stop to avoid debris in roadway. Took vehicle to a brake shop and they found that right front wheel was locked. This is the third time I have had the EXACT same problem with the brake system. The previous times, the problem occurred during nice weather and with windows open I smelled the burning brake pads and was able to get the problem fixed before it became a hazard. On the first previous incident, the repair required replacement of both front brake caliper, rotors, and pads. On the second previous occasion less than 20,000 miles ago BOTH front and rear calipers, rotors and pads were replaced. This is apparently a known defect in the 2004 Toyota 4Runner, yet Toyota has not conducted a recall to fix an extremely dangerous and ongoing problem. NOTE: I originally purchased the vehicle in New Jersey in 2004 and a Virginia Toyota dealer (Koons Toyota) worked on the brake system multiple times (2005-2006) and finally replaced the entire system.

Filed Nov 9, 2021 · Acceleration · 240,000 miles · OH

The contact owns a 2003 Toyota 4Runner. The contact stated while his wife driving 60 MPH with the cruise control activated, the accelerator pedal was depressed, and the vehicle rapidly started to accelerate. The contact stated no warning light was illuminated. The driver depressed the brake pedal to stop the vehicle and parked on the side of the road. The driver was able to restart the vehicle and drive to her destination. The contact stated that in October 2021 his wife experienced a similar failure. The contact also stated that on 11/8/2021 while his wife driving 55 MPH and depressing the accelerator pedal, the vehicle accelerated quickly. The contact stated no warning light was illuminated. The driver depressed on the brake pedal with both feet and shifted gear to neutral to slow the vehicle. The driver stated she saw smoke coming from both front brakes. The drive was able to park on the side of the road. The driver stated that the brake pedal was seized on the floorboard. The driver stated she applied the parking brake to release the brake pedal. The driver was able to drive to her residence. The contact stated that his wife had experienced the failure on 3 different occasions. The vehicle was not diagnosed or repaired. A dealer was not contacted. The VIN was associated to the federal safety agency Campaign Number: 11V113000 (Vehicle Speed Control) and the federal safety agency Campaign Number: 03V146000 (Fuel System, Gasoline). The manufacturer had not been informed of the failure. The failure mileage was approximately 240,000.

Filed Oct 9, 2021 · Steering · MA

The steering became almost unresponsive and I could not turn the steering wheel while driving. I brought it to a repair shop and they said the intermediate steering shaft and u-joints were rotted out and rusted to where it seized up. The vehicle only has 55k miles on it and I don’t live by the ocean. The parts were repaired by a shop and steering feels like new again. Had this seized up on the highway or at high speeds it could have been very bad. There were no warning lamps or issues with steering before

Filed Apr 29, 2020 · Body · 75,000 miles · IL · fire

We have a 2004 4runner with extreme body rust a corrosion which has caused the failure of numerous components, brakes, gas tank, transmission lines, wheels and other suspension and exhaust items. We originally noticed this failure and began taking steps to correct areas of concern, but the excessive rust has prevented many repairs on suspension, brakes and other components. We recently had an incident that almost caused a roll-over when the brakes seized and the transmission lines failed. I can describe this in more detail at request. When we try to remove bolts, brackets and associated hardware, they are seized, rounded off and/or broken. With no way to repair damaged parts or remove the rust, we may be forced to scrap a vehicle that is otherwise running perfectly. We have taking extreme measure to attempt to mitigate the continuing damage, but seem to have no option for existing damage. I do know there is 1 open investigation on this issue from 2018, the federal safety agency action number: dp18002. Original complaint number voq 11098055

Filed Mar 19, 2019 · Brakes · 103,000 miles · NY

I have gone through 2 sets of front brake calipers on my 2008 toyota 4runner. It is a common issue where over time, the calipers will seize up and stick on. The only way to tell that there is an issue is either by touch, smell, or feel. Touch, because the rotors get to be over 250 degrees and they cannot be touched. Smell, because the smell of burning brake pads is present feel, because there is a loss of braking. Other than these indications, there is no notice of seized calipers until it is too late. This is a common issue and has happened with most 4runner owners that I talk to. I'm surprised that this has not become an issue.

Filed Jan 3, 2019 · Brakes, Suspension · 70,000 miles · CA

My 2006 toyota 4runner limited has excessive rust corrosion throughout the undercarriage of the vehicle including but not limited to the frame, suspension, brakes, wheels, exhaust system and bolts/bracing. Since purchasing the vehicle, I have had to replace both front axles due to excessive rust at the recommendation of both the dealership and a third party mechanic. While driving, the skid plate detached from underneath the vehicle and was dragging beneath the car after the metal on the plate rusted out around the bolts. Similarly, the heat shield detached while driving on the highway after the bolts rusted out. When I replaced the front brakes (pads & discs), I was forced to purchase brand new calipers because the current calipers were so rusted and seized and the mechanic could not reattach them. I have continued to use toyota dealerships for scheduled maintenance and the consensus has been as follows: sell the 4runner because it is excessively rusted would be a money pit to repair. Currently, the dealership has recommended I replace the steering rack and pinion due to leaks caused by rust. Moreover, the vehicle has duel exhaust leaks in both exhaust manifolds due to excessive rust. On multiple occasions the dealership told me they could not perform the work because of excessive rust. It has cost me thousands to repair and maintain, all of which is a result of extensive rust. The suspension and frame, including the shocks, struts, and bolts are excessively rusted and I have been urged to repair or sell the vehicle by multiple mechanics and dealerships, though the cost to do so would far exceed the cost of the vehicle. All of the aforementioned is detailed in paperwork from the dealership and supplemented by paperwork from third party mechanics here in san diego. The vehicle has 90k miles on it and has followed scheduled maintenance meticulously.

Filed Jun 5, 2018 · Brakes · 100,000 miles · OR

Front brake caliper pistons seized up causing me to go through a stop light. See enclosed video. Please review all the complaints regarding toyota 4runner caliper pistons seizing up. This is a serious design defect that requires your immediate attention.

Filed Jan 3, 2018 · Electrical, Engine · 28,000 miles · NC

Tl* the contact owns a 2015 toyota 4runner. While driving in the left lane at approximately 70 MPH, the vehicle lost power. The contact stated that the vehicle seized and was unable to be moved. The engine was still running, but the vehicle would not accelerate. All the indicators on the instrument panel illuminated at the time of the failure. Modern toyota (3178 peters creek pkwy, winston-salem, nc 27127) diagnosed the vehicle, but the cause of the failure was undetermined. The vehicle was not repaired. The manufacturer was not notified of the failure. The VIN was unknown. The approximate failure mileage was 28,000. *tt

Filed Sep 11, 2017 · Body · RI

While changing the brakes and roters, it was noticed that the frame where the gas tank straps attach, is completely rusted and rotted through. Several areas on the frame are rotted through. The mechanic stuck his finger right through my frame. Also, there is body rust all around the back window, causing water to get into the back door, causing the 3rd brake light to not work, and causing the latch to lock and keep the hatch closed is seized due to rust.