Which parts fail
Components named in complaints (struts, shocks, control arms, ball joints, springs).
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.
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. …
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
After buying this vehicle I was underneath vehicle to repair a axle seal leaking and found extensive frame rust on passenger rear of frame. By extensive I mean the frame was rusted completely through! I have lived in ohio all of my life and have never seen a vehicle with this mileage and of this year have such severe frame rust! After further inspection I noticed rear end housing was also severely rusted. The rust on the frame is severely perforated at point where trailing arm for the rear end attaches to the frame! I was not aware of this issue before buying vehicle but after some research have found that this is definitely a manufacturer defect of some sort! These vehicles are not safe to drive with these frames in this condition and Toyota is aware of this!
I took my vehicle in for a routine oil change recently and the technician said that I have some major rust issues on my rear axle and drivetrain. He should me when it was on the lift. He explained to me that the bolt and clip than holds the brake line down on the rear differential had rusted and broken off of the differential cover. The rear differential is now leaking gear oil. The technician advised me that it is too risky to attempt to repair as it May cause the entire differential to be damaged and the whole rear axle would need to be replaced. The technician also said that it is a risk to drive the vehicle and is possibly unsafe to keep driving. He stated that it is unknown how much longer I would be able to drive it until the rear axle ceases.
When I had my state inspection in January of 2020, the machanic told me the frame of the vehicle will not pass inspection again. It is severely rusted through and in his opinion is unsafe to drive. A few weeks later, I was travelling to my father's residence and the brakes gave out. The technician that repaired my brake line also told me and documented on the bill that the truck is really not safe to drive. I have owned this vehicle for 18 years, and only driven it five winters. I wash the truck numerous times during the winter to remove salt. It is my only vehicle, and I cannot afford a new one. Why wasn't this included in the frame recall from Toyota?!? Now I'm nervous about my safety and those on the roadways.
Tl* the contact owns a 2002 Toyota 4runner. The contact stated that the rear trailing arm on the vehicle prematurely deteriorated and fractured. The vehicle was towed to the contact's residence and then towed to an independent mechanic. Who diagnosed that the rear end housing and axle differential needed to be replaced. The vehicle was not repaired. The manufacturer was notified of the failure. The approximate failure mileage was 64,000. Updated 11/20/15 the consumer stated the vehicle should not have to be repaired at the owner's expense. The rear differential had to be replaced. The frame of the was also badly rusted. Updated 2.3.16
Frame rust on the inside portion for the frame. 33" hole rusted through completely on passenger side. Rust continues about 80% of the way through the rear lower control arm mount. Driver's side has a similar amount of severe rust that has weakened the structural integrity of the frame to the point where it is no longer safe to drive. Should the co troll arm mount finish rusting through, the axle will no longer be attached to the frame on that side. There is noticble flex and sound associated with the frame rot. It is only a matter of time before the control arm mount disconnects completely, or the frame buckles.
Vehicle was stationary. While replacing exhaust system components. Found what appeared to be minor rust on the passenger (right) side rear suspension mount. Further investigation uncovered a larger area of rust along the 3 welds on the inner frame rail. Cut / ground the metal back to good metal and am in the process of patching for my yearly maine vehicle inspection. Either Toyota has built an inferior frame or the newer chemicals being used to keep the roads clear in the winter to be the cause of this rust which could cause the rear suspension to fail at this point in the frame and cause a accident.
Related recalls
Suspension › Front › Control arm › Lower ball joint
On certain sport utility vehicles, due to a manufacturing issue in the front suspension lower ball joint, there is a possibility that the surface of the ball of the joint May have been scratched. The ball joint May eventually experience excessive wear and looseness, resulting in increased steering effort.
Remedy: Dealers will replace the front suspension lower ball joints free of charge. The recall began on July 5, 2005. Owners May contact Toyota at 1-800-331-4331.
Suspension complaints in other 4Runner years
Frequently asked questions
How common are suspension problems on the 2002 Toyota 4Runner?
NHTSA has 49 complaints about the suspension of the 2002 Toyota 4Runner, 22% of the model year's 225 complaints. The component named most often is front › control arm › lower ball joint (8 mentions).
Is there a recall for 2002 Toyota 4Runner suspension problems?
Yes — NHTSA recall 05V-225 (lower ball joint, May 17, 2005). Recall repairs are free at authorized dealers.
At what mileage do 2002 Toyota 4Runner suspension problems start?
Half of the complaints with a recorded mileage happened before about 132,000 miles, and 3% before 25,000 miles.
Is it dangerous?
Owners linked 5 crashes, 0 fires and 5 injuries to suspension 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.