Which parts fail
Components named in complaints (doors, hood, frame, rust, paint and trim).
Mileage when the problem started
Owner reports
Selected complaints filed with NHTSA by 2002 Toyota 4Runner owners, lightly cleaned up (personal details are redacted by NHTSA).
The contact owns a 2002 Toyota 4Runner. The contact stated that while driving 60 MPH through a slight right curve, the vehicle independently shifted from side to side without warning nearly causing the vehicle to flip. The contact had an independent mechanic inspect the vehicle and the mechanic discovered severe corrosion throughout the entire subframe of the vehicle. The mechanic informed him that the entire subframe needed to be replaced to ensure safe driving. Neither the dealer nor the manufacturer had been notified of the failure. The vehicle had yet to be repaired. The failure mileage was approximately 115,000.
The contact owns a 2002 Toyota 4Runner. The contact stated that while inspecting underneath the vehicle, he noticed that there was a hole in the subframe and that the subframe and sway bar were corroded. The vehicle was not diagnosed or repaired by an independent mechanic or dealer. The manufacturer was not made aware of the failure. The failure mileage was approximately 160,000.
The contact owns a 2002 Toyota 4Runner. The contact stated that while receiving routine maintenance repair on the vehicle, the independent mechanic informed the contact that the subframe was rusted. The dealer was not contacted. The vehicle was not repaired. The manufacturer was not notified of the failure. The approximate failure mileage was 136,000.
Had vehicle inspected on Oct. 1 ,2021 for road trip to North Carolina from Washington, DC. Was informed that my vehicle is unsafe by the automotive shop (name withheld) due to [rusting] frame front suspension components' threads rusted off on bolts that hold suspension, control arms, and shocks on both front and rear areas + body of vehicle located where shocks bolt to the body. I also had two other shops (names withheld) assess the state of the frame and suspension + and was told that the vehicle has maybe 1 year or so until the frame falls apart. Given I am the original owner, have gargage-kept my vehicle, have very low-mileage - 74,000 miles, and have maintained the vehicle immaculately and am aware of rusting problems with other Toyota [truck] frames, etc. this seems to be a defect in the manufacturing process. …
Frame is excessively rusted. The recall that already exists for this issue only covers certain frames from Japan made with this steel. However, the same frames were imported to America and a large percentage of 4Runners were made with the same steel and didn't receive a recall. Mine is one of them.
After having my 4 runner in for routine maintenance, my mechanic informed me that my frame was in bad condition and rusting through. Doubtful it has a year left and he advised me to junk it as fast as I can. 180;000 miles - so much for Toyota's lasting a long time.
Takata recall. I have a rusty frame that needs to be addressed for safety reasons I was driving on the highway at 55 MPH frame cracked and I almost died because of it toyotas have poor frame that should be recalled
The frame of this 4runner has been experiencing excessive rust since the time I got it used from a dealer. Once their undercoating wore off, my mechanic replaced rusted up brake lines back about 9 years ago. He said it was because the frame was very rusty and they did a new rust treatment. For the past few years I have been battling issues related to the frame. A plate was put in to strengthen an area. It only has 164K on it, I rebuilt the transmission at 125K, and the body is in good shape. Just that the rust is spreading everywhere underneath. We tried to get it addressed in the previous Toyota frame recall but it was not for this age for whatever reason. Every repair has been more difficult due to rusting bolts, mufflers rusting early, brake lines busting due to rust, the tow hitch rusted through. Now there is a gaping hole in the rear side of the frame supporting the cab. …
Leaving work Friday of labor day weekend 2018 I noticed the smell of gas. My co-worker also looked, and observed a puddle of gasoline under the car. Since the dealer was close, I took the risk to drive it the dealer. The dealer is heritage Toyota in baltimore maryland. The car has only 91000 miles on it. The entire bottom of the car is rusted out. This is what caused the fuel leak. The frame is also rusted out to the point of not being safe anymore. My complaints are these: 1. The underside of the car completely rusted out. 2. Other Toyota trucks of the same year are having their frames replaced by Toyota. 3. My Toyota was serviced with me letting the dealer do "anything it needs". I estimate spending about $15,000 at this dealer. Never once was I told there was a rust problem. …
We purchased a 4runner for our 18 year old daughter to drive thinking it would be safe, ESP in mn. She was driving home from college (130 miles) and noticed it had a bad vibration, especially over 40 MPH. It was very difficult to drive. We were out of town and when we got back, brought it to the shop, only to be told the frame was responded beyond repair (see photos). Not only does that scare me for my daughter, but she has been driving it a few years and had friends and other family members in the vehicle. The vehicle has relatively low miles for it's age and based on toyotas reputation of longevity, we never expected this sort of issue. We're thankful she wasn't hurt, but are concerned about others driving a vehicle and not knowing it could literally break in half while driving down the road!
NHTSA investigations
Frame corrosion
On August 7, 2018, the Office of Defects Investigation (ODI) received a defect petition from Mr. Gary Weinreich alleging premature frame corrosion failure in model year (MY) 2002 - 2006 Toyota 4Runner vehicles. The petitioner based his request upon a corrosion-related front suspension failure he experienced in his MY 2005 Toyota 4Runner, a class action lawsuit settlement involving other Toyota products, and other…
Body complaints in other 4Runner years
Frequently asked questions
How common are body problems on the 2002 Toyota 4Runner?
NHTSA has 88 complaints about the body & structure of the 2002 Toyota 4Runner, 39% of the model year's 225 complaints. The component named most often is body (74 mentions).
Is there a recall for 2002 Toyota 4Runner body problems?
No. NHTSA lists no body & structure recall for the 2002 Toyota 4Runner, though it has 1 recall for other components. If the problem is widespread, a repair may still be covered by an extended warranty or a manufacturer service bulletin — ask a dealer.
At what mileage do 2002 Toyota 4Runner body problems start?
Half of the complaints with a recorded mileage happened before about 140,000 miles.
Is it dangerous?
Owners linked 2 crashes, 0 fires and 5 injuries to body & structure problems on this model year. If you notice symptoms, have the car checked before driving further.
Source: U.S. National Highway Traffic Safety Administration (NHTSA) — owner complaints through October 20, 2026, recalls and defect investigations; fuel economy from the EPA. Complaints are unverified reports and are not proof of a defect. How we rate model years.