2001 Toyota 4runner Suspension Problems

Your vehicle's frame has rusted completely through in places. Your mechanic has determined the damage is too severe to safely inspect and recommends the vehicle should not be driven. Fixing this would require extensive frame repair or replacement work by a professional shop.

While driving on the highway at 65 mph, your 4Runner suddenly shook and swayed violently, making it very difficult to control. A Toyota dealer found that the frame was corroded completely through, and the rear trailing arm had separated from the frame—making the vehicle unsafe to drive and unrepairable due to the extent of the rust damage. Addressing this issue would require frame replacement or structural welding, which may not be feasible given the severity of the corrosion.

While driving at 15 mph, you heard thumping and clicking sounds from the front of your vehicle, and the front passenger side suddenly dropped. A mechanic found that the lower ball joint had failed completely and was touching the ground, requiring replacement. This happened at around 275,000 miles. The repair involves replacing the worn lower ball joint.

During an oil change, you were told your vehicle's frame has severe rust damage. When you contacted Toyota, they said no recall exists for your model year and they can't help. You're left with a mechanically sound vehicle that may not be safe to drive due to structural rust.

THE FRAME RUSTED OUT AND IS VERY DANGEROUS TO DRIVE .THERE ARE MANY COMPLAINTS INVOLVING THE FRAME RUST ON THE 4 RUNNERS AND TOYOTA WILL NOT HELP WITH THE PROBLEM

THE FRAME IS RUSTING OUT VERY BADLY, THUS LEAVING VEHICLE UNABLE TO OPERATE IT SOON.

FRAME RUST ON LEFT REAR FRAME AT ATTACHMENT POINT OF LOWER CONTROL ARM WHICH LOCATES AXLE TO FRAME. RUST HOLES IN FRAME AROUND THIS SAME AREA.

BROUGHT THE CAR IN FOR REAR END REPAIR AND HAD 2 REPUTABLE MECHANICS REFUSE TO REPAIR THE TRUCK BECAUSE THEY SAID THE FRAME WAS SO BADLY RUSTED THAT IT WOULD BE A HAZARD TO EVEN DRIVE THE TRUCK IRREGARDLESS OF ANY REPAIR THAT THEY COULD PERFORM

THE FRAME HAS SUFFERED SERIOUS RUST THROUGH ALSO DESCRIBED AS "FRAME ROT" IN POSTINGS ON LINE OF TOYOTA 4-RUNNER PROBLEMS. THIS RUST THROUGH HAS MADE THE VEHICLE UNSAFE AND CURRENTLY UNUSABLE. THE RUST WAS DISCOVERED WHEN THE ENTIRE REAR AXLE WAS REPLACED AT MY EXPENSE. TOYOTA WOULD NOT ALLOW THAT THEY WERE RESPONSIBLE FOR FAULTY MANUFACTURING OF THE REAR AXLE EITHER WHICH WAS YET ANOTHER SAFETY CONCERN. *TR

LEFT SIDE FRAME ROTTED OUT. *TR

THE UNDER CARRIAGE HAS BEEN RUSTING SINCE I NOTICED APPROX. 4 YRS AFTER PURCHASE. I NOW HAVE BEEN UNABLE TO PASS INSPECTION OR DRIVE VEHICLE SINCE ENTIRE UNDER CARRIAGE IS COMPLETELY RUSTED OUT. WHEN ATTEMPT WAS MADE TO PLACE ON LIFT TO OBSERVE IT BEGAN TO CRACK OR SPLIT . I HAVE ONLY 87000 MILES ON IT AND THE REST OF VEHICLE IS CLEAN AND BASICALLY RUST FREE. IT IS MARCH 27 , 2015 AND HAS BEEN SITTING IN DRIVEWAY FOR LAST 3 YRS. THE TOYOTA DEALERSHIP IN WAPPINGERS FALLS STATED THAT TOYOTA IS PLANNING ON REPAIRING BUT IS UNCERTAIN AS TO WHEN. AT PRESENT THE BACK PARKING LOT IS FILLED WITH NEW UNDER STRUCTURES FOR OTHER MODELS.I WOULD LIKE TO KNOW WHEN THIS ONGOING TERRIBLE AND DANGEROUS PROBLEM WILL BE REPAIRED. *TR

ON ROUTINE CHECK AND INSPECTION, TOYOTA ARLINGTON AND TOYOTA SCHAUMBURG CALLED MY ATTENTION REGARDING A PREMATURE RUSTING ON THE UNDERBODY FRAME AND RESULTED IN A LINEAR HOLE BY THE REAR LEFT AND RIGHT PORTIONS OF THE VEHICLE. THIS ACCORDING TO THE SERVICE ADVISORS OF BOTH TOYOTA DEALERSHIPS MAY MAKE THE VEHICLE UNSAFE TO OPERATE AND MAY RESULT TO UNCONTROLLED STABILITY DURING DRIVING. *TR

ON OCTOBER 11TH 2014, I WAS DRIVING MY 2001 4RUNNER, ON MY WAY TO WORK. HAD JUST TURNED OFF A ROAD WITH A SPEED LIMIT OF 55. AS I HIT 35MPH, MY CAR COMES TO A JOLTING STOP WITH A LOUD BANG AND DRAG ON THE TIRES. THE CAR STILL RAN, BUT THE CAR WOULDN'T MOVE. I HAD TO FINISH WALKING TO MY JOB, AS I WAS CELLPHONE-LESS AT THE TIME. I HAD TO PAY TO HAVE MY CAR TOWED HOME, MISSING AN ENTIRE DAY'S WORK, WHICH WAS A LOSS OF 120$. THE GUY WHO TOWED ME TOLD ME IT WAS DEFINITELY SOMETHING TO DO WITH MY REAR END. SO I HAD A FAMILY FRIEND WHO IS A RETIRED MECHANIC LOOK IT OVER TO SEE IF HE COULD SPOT WHAT THE PROBLEM WAS. FIRST THING NOTICED WAS MY EMERGENCY BREAK WAS ON AND FROZEN. THEY REMOVE IT, CLEAN IT, PUT IT BACK ON. I START THE CAR, GO TO MOVE IT AND THERES A CONTINUOUS LOUD BANG AND THE CAR AGAIN COMES TO THE STOP. THE EMERGENCY BREAK FROZE AGAIN. THEY ONCE AGAIN TAKE IT OFF, AND SO FAR IT HASN'T REFROZE. HOWEVER, MY CAR IS STILL MAKING THE LOUD BANGING NOISE COMING FROM THE REAR END, WHICH THEY HAVE CONCLUDED IS COMING FROM THE REAR DIFFERENTIAL HOUSING UNIT. WHICH THEY FOUND A DECENT SIZED HOLE IN, WHICH IT APPEARS SOMEONE TRIED TO COVER WITH A YELLOW GLUE TYPE SUBSTANCE. I JUST BOUGHT THE CAR, AND AM NOW CARLESS. AS I HAVE 2 SMALL CHILDREN, AND CANNOT AFFORD TO FIX A PROBLEM THAT CAN COST UP TO $3,000 TO FIX. LUCKILY I WAS ONLY GOING 35 MPH WHEN IT BROKE, AND THERE WAS NO ONE FOLLOWING BEHIND ME, OR I WOULD HAVE BEEN RE ENDED, AND HAD MORE TO FIX THAT I ALREADY DO. THIS IS A HUGE PROBLEM WITH THE MODEL CAR, AND TOYOTA REALLY NEEDS TO ISSUE A RECALL ON THE DIFFERENTIAL UNIT!!! IT'S FAIRLY DANGEROUS. I LOVED THIS CAR BEFORE THIS INCIDENT. BUT NOW IT'S USELESS TIL I CAN AFFORD THIS FIX. *TR

VEHICLE FRAME IS RUSTING TO THE POINT OF PERFORATION. I DISCOVERED TODAY TWO HOLES, ONE ON EACH THE DRIVER AND PASSENGER SIDE, INNER FRAME RAILS JUST BEHIND THE REAR CROSSMEMBER. MY CONCERN IS IT MAY BE ROTTING FROM THE INSIDE OUT. IS THE MANUFACTURER GOING TO ISSUE A RECALL ON THESE FRAMES AS THEY HAVE DONE ON TACOMAS AND TUNDRAS? THIS CAR IS IN EXCELLENT CONDITION OTHERWISE AND I HAD PLANNED TO DRIVE IT FOR MUCH LONGER DUE TO ITS HANDLING AND SAFETY. *TR

THE 4RUNNER HAS DEVELOPED SURFACE RUST ON THE FRAME UNDERNEATH THE CAR. THE RUST IS ALSO APPARENT ON SUSPENSION COMPONENTS AND BRAKES. *TR

I WAS GOING OVER A RAIL RD CROSSING, AND THERE WAS A LOUD BANG AND KNOCKING AFTER. BROUGHT IT TO A SHOP, AND THEY SAID THAT MY DRIVER SIDE UPPER, REAR SHOCK WENT THROUGH MY SHOCK MOUNT. *TR

WHEN DRIVING AT 70 MPH, THE VEHICLE VIBRATES ON THE HIGHWAY. I HAVE TAKEN THE VEHICLE CONSTANTLY TO THE DEALERSHIP FOR OVER TWO YEARS COMPLAINING ABOUT THIS PROBLEM AND THEY ALWAYS TOLD ME THAT NOTHING WAS WRONG. TODAY (5/10/14), THE MECHANIC AT THE DEALERSHIP PUT THE TRUCK ON A RACK AND RAN THE CAR AT 45 MPH AND THERE WAS VISIBLE VIBRATION COMING FROM THE DRIVE SHAFT AND A LOUD NOISE THAT I COULD NEVER HEAR FROM WITHIN THE VEHICLE. ALL THIS TIME, I HAVE BEEN DRIVING A VEHICLE THAT I WAS UNAWARE COULD HAVE SNAPPED APART. THE SOUND CANNOT BE HEARD IN THE CABIN, SO I COULD NOT EVEN REPORT THAT AS A PROBLEM UNTIL TODAY. I PURCHASED THREE SETS OF NEW TIRES, HAD SHOCKS AND STRUTS REPLACED, AND BRAKE PADS TO NO AVAIL. FINALLY, AFTER SEARCHING THE WEB YESTERDAY, I REALIZED THAT THIS IS A COMMON PROBLEM WITH OTHER VEHICLES OF THE SAME MAKE AND MODEL. I'M NOT SURE IF THIS PROBLEM HAS CAUSED INJURY TO OTHERS, BUT THERE SHOULD BE A RECALL. THIS COULD CAUSE A POTENTIALLY FATAL ACCIDENT IF THAT SHAFT BREAKS. I READ THAT FOR SIMILAR MODELS (TOYOTA AND LEXUS), THE MANUFACTURER REPLACED THE PARTS UNDER WARRANTY, BUT NOTHING FOR THE 4RUNNER. THE DEALERSHIP IS CHARGING OVER $700 FOR THIS REPAIR. *TR

DRIVING DOWN THE HIGHWAY IN 2001 TOYOTA 4-RUNNER GOING ABOUT 60 AND ALL OF A SUDDEN THE REAR END/TIRES LOCKED UP AND GOT IT TO THE SIDE OF HIGHWAY BARELY AND THEN IT STARTED SMOKING REALLY BAD. VERY LUCKY THAT IT DIDN'T CAUSE A WRECK OR NO ONE GOT HURT. CAN'T DRIVE IT OR NOTHING, MAKES A LOUD KNOCKING NOISE IN THE REAR END AND ALSO WHEN YOU TURN THE KEY ON INSIDE THE VEHICLE ALL LIGHTS ARE ON AND ITS MAKING A TERRIBLE BUZZING NOISE. SO HAD TO HAVE IT TOWED AND THAT COST ME ALSO AND I NEED THE WHOLE REAR DIFFERENTIAL AND THAT'S A LOT OF MONEY. I'VE SEEN OTHER PROBLEMS/COMPLAINTS ABOUT THE SAME THING THAT HAPPENED TO MINE. I REALLY THINK SOMETHING SHOULD BE DONE ABOUT IT, TOYOTA SHOULD BE FIXING THE PROBLEM AND WE SHOULDN'T HAVE TO PAY FOR IT. HOPEFULLY SOMETHING GETS DONE ABOUT THIS. *TR

3RD GENERATION 2001 TOYOTA 4RUNNER WITH EXCESSIVE FRAME AND BODY RUST. THE GAS TANK STEM IS RUSTED, THE REAR DIFFERENTIAL IS LITERALLY POROUS AND LEAKING OIL DUE TO EXCESSIVE RUST. REAR BUMPER IS RUSTED, SPARE TIRE MOUNT IS RUSTED. OTHER AREAS OF RUST ARE TOO NUMEROUS TO LIST. REPAIR SHOP SAID CAR IS NOT WORTH FIXING. DANA CORP THAT MADE FRAMES FOR TOYOTA TACOMAS/TUNDRAS THAT WERE RECALLED ALSO IS BEST KNOW FOR REAR DIFFERENTIALS. WHY WEREN'T THE 4RUNNERS INCLUDED IN THE RECALL/BUYBACK BY TOYOTA? *TR

THE REAR DIFFERENTIAL ON MY TOYOTA 4RUNNER RUSTED SO BADLY IN 9 YEARS OF OWNERSHIP THAT THE STRUCTURAL STEEL FRAME THAT SUPPORTS THE DIFFERENTIAL GEARS (THE HOUSING) CRACKED AND OIL SPILLED OUT ON THE ROAD. I DISCOVERED THE RUST DURING THE YEARLY STATE INSPECTION AND CONSEQUENTLY HAD THE DIFFERENTIAL INSPECTED BY MY TOYOTA DEALER (BERLIN CITY PORTLAND, ME) A FEW MONTHS BACK AND THEY SAID IT WAS STRUCTURALLY SOUND BUT RUSTY. I AM AN ENGINEER AND CLEARLY IT WAS NOT STRUCTURALLY SOUND OR IT WOULD NOT HAVE FAILED IN SHORT ORDER AS IT DID.... THIS FAILURE COULD HAVE CAUSED THE REAR WHEELS TO LOCK UP RESULTING IN A SEVERE ACCIDENT. THIS RUST PROBLEM IS COMMON ON MOST TOYOTA TRUCK FRAMES AND DRIVE TRAINS OWNED IN THE NORTH EAST. TOYOTA HAS ELECTED TO REPAIR THE TRUCKS AT NO COST BUT NOT THE 4RUNNERS WITH THE SAME FRAME AND DIFFERENTIALS. THIS IS DANGEROUS AS [XXX]... THEY PUT ME AND MY FAMILY AT GRAVE RISK.... INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6). *TR

THE SUSPENSION RECALL ON MY 2001 TOYOTA 4RUNNER WAS DONE AT AROUND 60K MILES. IT NOW HAS 116K MILES AND THE PROBLEM IS BACK,I CAN TURN MY STEERING WHEEL ABOUT 1/2" IN EITHER DIRECTION AND NOT HAVE THE WHEELS MOVE,WHEN DRIVING THE STEERING WANDERS AND OCCASIONALLY GRABS IN WHAT FEELS LIKE A FLAT SPOT..THE CAMPAIGN NO IS 05V225000. *TR

WHEN ON A LONG HIGHWAY TRIP ON THE WEEKEND OF JUNE 7, 2008, MY HUSBAND NOTICED BLACK SPOTS ON THE REAR WINDOW OF OUR 2001 TOYOTA 4RUNNER (121,000 MILES). HE CLEANED IT OFF TO SEE IF IT RETURNED AS WE RESUMED OUR JOURNEY. WHEN WE NEXT STOPPED SEVERAL HUNDRED MILES LATER, THE BLACK SPOTS WERE ON THE ENTIRE REAR OF THE VEHICLE. MY HUSBAND CHECKED BENEATH THE REAR OF THE VEHICLE AND SAW TRANSMISSION FLUID DRIPPING OUT OF THE DIFFERENTIAL. WE THEN TOOK THE VEHICLE TO A MECHANIC WHO REPORTED THAT THE REAR AXLE HOUSING WAS COMPLETELY CORRODED TO THE POINT OF FAILURE, AND THAT IT WAS BEYOND REPAIR, AND THAT HE HADN'T EVER SEEN THIS ON A CAR OF THIS AGE AND MILEAGE. HE INFORMED US THAT TOYOTA HAS RECENTLY RECALLED TACOMA VEHICLES FROM THE SAME YEAR FOR SIMILAR CORROSION PROBLEMS. WE CONTACTED TOYOTA AND THEY SAID THERE WAS NOTHING THEY COULD DO FOR US. WE ARE LEFT WITH A VEHICLE THAT IS BEYOND REPAIR THAT WE ARE UNABLE TO SELL, AND WE HAVE MAINTAINED IT IN ACCORDANCE WITH THE MANUFACTURER'S GUIDELINES. PLEASE HELP. *TR THE CONSUMER WAS INFORMED THE ENTIRE REAR AXLE INCLUDING THE AXLE, DIFFERENTIAL, BRAKES, AND EXHAUST SYSTEM WERE CORRODED BEYOND REPAIR. UPDATED 08/27/08. *JB

I PURCHASED A USED 2001 TOYOTA 4 RUNNER 4 WHEEL DRIVE LAST YEAR WITH APPROX 88 K MILE. PRIOR TO GIVING IT TO MY DAUGHTER I REPLACED THE TIRES ( GOODYEAR) AND TOOK THE VEHICLE TO MY LOCAL TOYOTA DEALERSHIP ON 6-2-2007 REQUESTING A FULL CHECK OF THE VEHICLE TO VERIFY ROAD WORTHINESS PRIOR TO GIVING IT TO MY 16 YEAR OLD DAUGHTER. THEY SUGGESTED AND PERFORMED 90 K MAINTENANCE PACKAGE INCLUDING SUSPENSION INSPECTION AND FRONT END ALIGNMENT. SHE RETURNED TO VIRGINIA AND HAS BEEN DRIVING IT DAILY ON PAVED ROADS TO HIGH SCHOOL. SHE HAS NOT TAKEN IT OFF ROAD OR USED THE 4 WHEEL DRIVE. LAST WEEKEND SHE WAS SLOWLY TURNING INTO HER FRIENDS DRIVEWAY AND THE RIGHT FRONT WHEEL BROKE OFF THE AXLE COLLAPSING THE WHEEL AND RIPPING OUT THE FRONT AXEL. A STATE TROOPER PASSING BY INDICATED AT HIGHWAY SPEEDS THIS LIKELY WOULD OF FLIPPED THE VEHICLE. THANK HEAVENS SHE WAS GOING LESS THAN 10 MPH. THE VEHICLE WAS TOWED AND AT A LOCAL REPAIR SHOP IT WAS NOTED THAT THE LOWER BALL JOINT "DROPPED DOWN" TRIGGERING THE CATASTROPHIC FRONT END FAILURE. TOYOTA RECALLED 210,000 AXLES ON THE PRADOS VEHICLE ( NOT DISTRIBUTED IN USA) WHICH IS ON A SIMILAR PLATFORM AS THE 4 RUNNER. BLOG ENTRIES DESCRIBE SIMILAR FAILURES WITH THE WHEELS SNAPPING OFF. I CONTACTED MY TOYOTA SERVICE MANAGER AND DESCRIBED THE FAILURE. I REQUESTED HE EVALUATE AND ASKED IF THEY MISSED THIS ON THEIR INSPECTION IN JUNE. I ALSO REQUEST THAT THEY COVER THE REPAIR COSTS OF APPROX. $600.00 TO INCLUDE A DETAILED INSPECTION AND L BALL JOINT REPLACEMENT. HE INDICATED THEY WOULD NOT COVER THE REPAIR EXPENSES. MY CONCERN IS THIS FAILURE SHOULD NOT HAVE OCCURRED IF THE JOINT WAS ASSESSED AS ROAD WORTHY JUNE 2007 AND ONLY APPROX. 9 K MILES HAVE BEEN ADDED SINCE THEN WITH NO POTHOLE OR OFF ROAD TRAUMA NOTED. HOW CAN I BE ASSURED THAT THIS WON'T HAPPEN AGAIN MAYBE AT HIGHWAY SPEEDS WITH LIFE THREATENING OUTCOMES? HAVE SIMILAR COMPLAINTS BEEN FILED? DOES THIS WARRANT FURTHER INVESTIGATION BY YOUR AGENCY AND OR TOYOTA? *TR

FRONT WHEEL BEARING LOCKED UP. VEHICLE WAS TAKEN TO THE DEALER, AND DEALER WAS NOT ABLE TO DUPLICATE THE PROBLEM. *AK