Toyota FJ Cruiser ball joint problems

Filed Nov 5, 2026 · Body, Brakes · MA

1. The frame is defective. It's been rusting no matter how its cleaned or treated. It currently has at least 4 holes. This rust has spread to many suspension components as well as the underside of the floor. The vehicle eas NOT properly treated when built. I purchased this new in 2013. It currently has 69k miles. This rust that has consumed my vehicle has caused issues that make my vehicle unsafe to drive. 2. The problem has reproduced on its own mo matter the treatment attempted. 3. My car can NOT be safely driven to have these issues looked at. In the front the drivers side strut rotted off. Both front lower control arms are splitting apart from the rust. I recently had maintenance done including the serpentine belt. 4. These issues started slowly after purchase. Again, no matter how often the vehicle was cleaned or protected; the rust would come back. The floor panels on both sides near the edge are showing significant rust/rot. My car, if there where none of these defective issues woukd have an approximate value of 25k/29k. Right now with all the problems it has little to none. My car was never in an accident. Toyota has never had a recall on the fj cruisers frame as they had with the Tacoma. Had there been a recall and my frame was replaced; I woyld have a proper and SAFE vehicle now. Ive had a few estimates for fixing all the damage caused by the rusting defects. It ranges from 13k-17k. I have no safe or usable car because of Toyota never recalling the fj cruisers frame. Now that frame issue has spread across my car@

Filed Jul 10, 2023 · Body · CO

Frame rust prematurely affecting integrity of the rear lower control arm mounts. Back half of frame almost completely rusted through requiring a full frame replacement.

Filed Jan 26, 2023 · Brakes, Steering · OH

the brakes are constantly binding up due to rust and need replaced, recently ABS brake lines rusted off causing me to miss a stop sign, very dangerous, Upper rear control arm mount rusted and cracked completely off causing steering and braking problems and had to be replaced to even use this vehicle, , The front rack has been replaced due to excessive rust of lines and fittings, same with transmission cooler lines-rotted off...brake backing plates rotted off.. Even though I have had this undercoated and rust treated, the frame is rusting inside-out...frame braces, everything on the frame is rusted much more than one would expect, even in a salt state like Ohio....my safety was put at risk by faulty brakes, the frame is not safe under hard braking and may cause an accident, the dealer has seen this vehicle, a local independent says "get rid of it"...no warning lamps, just wild things happen with brakes, pulls left, pulls right, front, then back and this past time ...NONE!...only 111,000 miles.

Filed Oct 15, 2022 · Body, Suspension · OH

Backing out of my driveway we heard a slight pop and a dragging feel on the right passengers front.( thought I ran over a landscape brick) Stopped and inspected nothing was under the vehicle starting to leave my complex vehicle started to shake some. When I got up to 20 MPH it was obvious I should not drive. Called tow truck. Thought I needed ball joints or something similar. Mechanic said frame was completely rusted out and unfixable. The Toyota FJ cruiser is suppose to be a tough off road SUV which I never used for off road driving They even advertised how tough the frame is in commercials . I see there has been recalls for other Toyota models of SUV and trucks of the same year and their is a class action lawsuit already started I think in California. If I would have continued to the freeway A serious accident would had happened. I contacted Toyota and opened a case # [XXX] which after two communications they closed because there is no recall on the vehicle. The car is in great condition other wise. A frame should last more than 15 years on a truck \SUV designed for off road driving . her are some details of the pending lawsuit: Plaintiffs allege that a manufacturing defect causes excessive rust and corrosion to the frames of 2007-2014 FJ Cruiser vehicles. The suit claims the defect weakens the structure of the vehicle, therefore posing a serious safety threat to vehicle occupants. In some cases, vehicles failed to pass safety inspection and are no longer safe to drive. As a result, owners find themselves stuck with a vehicle that is no longer legally allowed on the roads with a greatly diminished resale value. Toyota Activity Marketed the FJ Cruiser with Special “Electrocoat Deposition” Rust Protection Coating Despite Toyota’s marketing highlighting the “Electrocoat Deposition” protective coating, plaintiff’s claim FJ Cruiser frames prematurely rust and corrode at an accelerated rate. The suit states Toyota had been aware of the frame defect, but fail INFORMATION Redacted PURSUANT TO THE FREEDOM OF INFOR

Filed Jun 6, 2021 · Body, Brakes · MA

Due to rust on my 2007 FJ Cruiser, I've had many unexpected expenses. I first was losing brake pressure and my brake lines had to be replaced after breaking when in a mechanic's shop. I've also replaced all four calipers, all the rusted pulleys on the engine, lower control arms that were so rusted that they had to be cut out, and hub assemblies for both front wheels. The hub assembly lead to a failed vehicle inspection for safety concerns. The exhaust pipe literally broke apart near the rear frame crossmember and was sitting on it, so had to be replaced. The exhaust manifold rusted apart and separated from the engine block, leading to dangerous fumes in the engine bay and horrible gas mileage. The O2 sensors were rusted in place and giving poor readings and had to be replaced. Turning the steering wheel became difficult and that was due to being extremely rusty, so it had to be replaced. Shifter cable and PRNDL switch had to be replaced due to not shifting into drive or lower gears. The front differential drain plug was so rusted that the dealership would not attempt to remove it. Now there are holes rusted through the body mount brackets, as well as the passenger side floor. The cargo area's floor where the charcoal EVAP canister connects to the vehicle has completely rusted through, and one of the subframe brackets rusted so badly that it was taken off by hand. Both subframe brackets need to be replaced. The rear control arm mounts are very thin due to extreme rust. My mechanic is now replacing coolant lines because they have rusted through and started to leak, and gas tank straps which were on the verge of failing.

Filed Apr 22, 2021 · Body · MA

Frame has severe structural rot at the lower control arm mount and left and right upper control arm mounts at the frame. And additional frame rust is the rear axle housing has rusted to the point of weeping oil. This is what I was told when I had it looked at. This fj is no longer able to be driven at this point. It was not in an accident, the frame is just rusting at an alarming rate compared to other toyotas I have owned.

Filed Oct 10, 2020 · Body · NY

Excessive rust on frame, chassis, tie rod ends and all other metal parts, although car is maintened properly, only 40k miles, garage parking, no off-road usage and no salt exposed.

Filed Aug 2, 2020 · Body, Suspension · NJ

Severe rust on critical suspension components despite frequen undercarriage washing and care. Control arms and tank straps will need to be replaced and mounts welded

Filed Jul 20, 2020 · Body, Suspension · 90,000 miles · HI

2007 toyota fj cruiser frame rotting from inside and out. Rear upper control arm mounts rusting looking like its about to break off. Unsafe to drive. 13 year old frame should not be anywhere near this condition.

Filed Mar 13, 2020 · Body · 183,000 miles · VA

Rust has decimated the frame of this vehicle resulting in the control arm mount to break away from the frame of the vehicle. The control arm is completely in tact. The part that broke is irreparable because it is the frame itself. No welding/body shop will touch it because they deem it unsafe even if welded back to rest of frame. It is being recommended not to attempt a repair and to install a new frame. Fortunately, this broke in a parking lot instead of on the highway where an accident would have happened or worse. Frame rust has been a problem with toyota trucks as I understand but to have a frame actually break is absurd.