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 2003 Toyota 4Runner owners, lightly cleaned up (personal details are redacted by NHTSA).
The contact owns a 2003 Toyota 4Runner. The contact stated that while the vehicle was at the tire retailer for tire replacement, the technician informed him that the subframe was corroded. The vehicle was then taken to an independent mechanic, who diagnosed that the passenger's side front and rear subframes were severely corroded, as well as the cross member. The mechanic advised the contact to stop driving the vehicle. The dealer was made aware of the failure and informed the contact that there was no recall associated with the VIN. The vehicle was not repaired. The manufacturer was not made aware of the failure. The failure mileage was approximately 165,000.
The contact owns a 2003 Toyota 4Runner. The contact stated that upon taking the vehicle to several independent mechanics for servicing, he was informed that the subframe was significantly corroded and needed to be replaced. The vehicle was not repaired. The dealer was not notified of the failure. The manufacturer was notified of the failure and informed the contact the vehicle was not covered under recall. The failure mileage was approximately 115,000.
The contact owns a 2003 Toyota 4Runner. The contact stated that while driving at limited speeds of 45 mph, the vehicle would wobble and swerve and was very unstable. The vehicle was taken to a Certified Auto Mechanic Shop and an independent mechanic who diagnosed that the failure was caused by severe rusting, perforation and corrosion of the rear subframe and suspension system. The vehicle was also driven to Muffler Shops in Bladensburg, MD on 8-20-2021, and on 10 -22-2021 to Hyattsville Toyota's Certified Toyota Collision Center for Repair Estimates of $4,000.00 and $7,268.00. The vehicle frame manufactured by Dana Holding Corporation which really requires fixing or replacing was not yet repaired. The Toyota manufacturer and local dealer Global Auto Outlet were notified of the failure. The approximate failure mileage was 1 85,000. …
Due to severe rust underneath the vehicle, there have been a few issues that have made the vehicle very unsafe to drive. Last week, both of my rear brake lines were completely done and leaking brake fluid leaving me with no brakes. This was due to rust and corrosion that had eaten the metal lines away. The radiator mounts are corroding, as well as the skid plate for my fuel tank and a few spots on my frame near the rear. I was not aware of the rust as I just got the vehicle a few weeks ago. I was driving in traffic when my brake light came on and I noticed my brakes didn't seem to be very effective and they eventually got the point where they were not working or slowing the vehicle at all. Once I took it to the shop and they put it on the lift, the mechanics pointed out just how bad the rust was.
Frame has major rust holes towards the front inside next to the catalytic converters. Hoping to get them repaired before frame failure. The frame design is similar to the 2005 to 2015 Tacomas, which experienced similar issues with rust damage causing frame integrity issues. Toyota had a program to replaced those frames, but not for the 4Runners. The issue seems to be caused by certain factory openings in the frame that allow road salt to enter into the frame cavity, and cause the inside to rust. Being next to the catalytic converter, the heat accelerates the rust. On my 4Runner, the issue has gotten worse in the last 2 years. I cannot understand why Toyota covered all other trucks/suvs that use this similar frame but ignored the 4Runner.
The frame on the vehicle is rusting out. If not repaired, serious injury could occur if the frame breaks. A compromised frame could cause serious injury if an accident occurs. The driver side main frame has a gaping hole on the inside and another hole forming underneath that is in close proximity to the larger hole. The entire back cross bar member supporting the bumper is rusting out as well as the front cross bar member. The vehicle was inspected in July 2020 and the dealership said the frame was OK and had plenty of life left in it. After getting a muffler installed at a local independent shop in October 2021, the hole grabbed the attention of the technician. After inspecting, rusty flakes kept falling away.
Excessive frame rust causing difficulty to keep vehicle on the road. No warning lamps, I noticed the rust starting years ago, now the rust is so bad that the frame is rusted through causing difficulty steering and loud crunch noises. I contacted Toyota Consumer Affairs explaining the rust concern and asked if I needed to take the vehicle to a dealership for inspection, they said it wasn't necessary (sounds like they don't want to admit the existence of a possible manufacturing defect). The vehicle is available for inspection. I feel like I would be doing a disservice to society if I continue to drive this vehicle on public roads due to the danger of injuring a pedestrian or another motorist.
The frame of my 4runner is so so rusted that my mechanic put his finger through a piece of the frame it is so unsafe for Mr and my grand children and EVERYONE ELSE on the road that it literally makes me sick. It'd the only vehicle I have so I have NO CHOICE but to drive it. It terrifying. It is available to inspect at anytime. I just bought this vehicle less than a year ago from a dealership and it so sad that they wld sell it to anyone knowing the frame was rusted its criminal in my opinion. It Is for sure a safety hazard to everyone. I hope that this investigation proves to help get all of these 4runners OFF THE ROAD. So that a preventable tragedy doesn't happen.
At the end of June 2021, while driving I experienced a loud clunk and grinding noise, with reduced control of steering and brakes on my 4Runner. I took the 4Runner to a Goodyear Automotive Service Center on Woodward Avenue in Royal Oak, Michigan, who told me that the vehicle was not driveable due to severe rust damage of the frame that resulted in a broken sway bar. I thought I should take it to the closest Toyota dealership in Troy, Michigan for advice and they responded that the vehicle was beyond repair and that a new frame would cost around $20,000. I could not leave my car there, and risked driving it home, where it has been parked ever since.
I have two 2003 Toyotas, a tundra and 4runner. The 4Runners frame is rusting out everywhere including the welds. My mechanic said it was getting to the point that it's dangerous to drive and if it was in a wreck the frame would likely fail under the stress. My tundra frame from the same year is immaculate. I believe the are similar frames. This is obviously a defect in the production based on my readings and is very common. The investigation was opened in 2018 and its now 2022, when will this get addressed!
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 2003 Toyota 4Runner?
NHTSA has 284 complaints about the body & structure of the 2003 Toyota 4Runner, 41% of the model year's 696 complaints. The component named most often is body (248 mentions).
Is there a recall for 2003 Toyota 4Runner body problems?
No. NHTSA lists no body & structure recall for the 2003 Toyota 4Runner, though it has 3 recalls 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 2003 Toyota 4Runner body problems start?
Half of the complaints with a recorded mileage happened before about 139,000 miles, and 5% before 25,000 miles.
Is it dangerous?
Owners linked 3 crashes, 0 fires and 0 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.