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 2004 Toyota 4Runner owners, lightly cleaned up (personal details are redacted by NHTSA).
The contact owns a 2004 Toyota 4Runner. The contact stated that he noticed that the tow hitch had separated from the frame and was laying on the ground. The contact stated upon inspecting the subframe of the vehicle, he noticed that the subframe to which the radiator mount was attached was severely corroded. The contact stated that upon changing the oil in the vehicle he noticed that the front passenger's side subframe had a significant size hole. The dealer was not notified of the failure. The vehicle was not diagnosed or repaired. The manufacturer was notified of the failure and provided case numbers to the contact. The failure mileage was approximately 224,000. The contact stated that their vehicle is not a part of the recall that affects other Toyota models although other 4Runners have experienced similar issues. It was recommended to the contact to sell or trade-in their vehicle. …
Frame started excessive rusting before 2011 when the vehicle had very low miles on it. I reported it to Toyota National headquarters in 2016. They knew about it but since they didn't have to replace the frames they didn't care. They offered me $1000 towards a new car. I could not afford a new car. I have been battling the rust ever since. I spent $4000 in the past 2 years. I was driving with a broken front axle!! Recently the rust corroded my brake fluid lines causing the lines to fail all at once. Luckily I was leaving my driveway. I had no brakes and was headed for the road. I hit the emergency brake and stopped at the road. Brake fluid fell out all over my driveway. I had to spend $400 getting my driveway resealed and $300 for the new brake lines which was really cheap. …
My steering became very loose with a lot of movement in the steering wheel. The universal joint in the steering column shaft was bad. Upon further investigation, both lower control arms on the front wheels were rusted through, (from the inside out), with one of them bent because of the lack of metal support that rusted away, which caused my wheels to be misaligned and hard to control. Upon additional inspection, the frame has rusted out in multiple places which could allow it to break in half. (pictures of one portion of the frame are attached.) I have had the steering column and lower control arms replaced but multiple body and frame shops state the frame is rusted too much to repair. I know Toyota recalled several models for frame rust issues but have not included the 4Runner, which I cannot understand. …
What component or system failed or malfunctioned, and is it available for inspection upon request? Response: Frame, Suspension, Airbags / Yes it is available for inspection. How was your safety or the safety of others put at risk? Response: Safety was put at risk due to frame & suspension failure due to severe rust. Also due to failure of deployment of AirBags. Rusted Frame Failure subsequently caused safety of Injured Party and other motorists to be at risk due to the Injured Party's 4Runner to dart across oncoming lane of traffic with no warning other than a swaying motion felt immediately before losing control. Once the Injured Party lost control of the 4Runner it crossed into oncoming traffic, progressing into the drainage ditch on the oncoming traffic side of highway. …
Purchased 4 runner from a Toyota dealer in 2018 with 130k miles. During routine maintenance in 2021 with 160k. The frame was found to have several holes and wide spread corrosion. It is absurd that Toyotas was let off the hook for frame replacements. I bought this truck from the dealer and it had structural frame issues that were not disclosed at the time of sale. Frames don't just fall apart apart in 4 years from normal driving. Clearly Toyota is ignoring the manufacturing deficits in there frames and still re-selling these as road worthy cars. It's absurd that Toyota was not required to replace these and not recall has been issued. People should not be able to buy/sell one off these vehicles they are not safe due to the frames rusting from the inside-out. They need to be recalled and removed from service.
The frame is damaged from excessive corrosion. The rear cross member that supports the trailer hitch and rear bumper is almost non-existent, which could result in the loss of the trailer being towed, and it will reduce the truck's rear impact resistance. The front right lower control arm has a 2'" x 3/8" lateral hole from corrosion, which could result in a catastrophic failure of the right front suspension system. The longitudinal frame members are compromised by corrosion which has penetrated through the steel in various locations. The front cross-frame member that supports the radiator is severely corroded. The frame to body mounts are showing signs of excessive corrosion which could result in the separation of the the body from the frame in an accident.
My Car was inspected by a Virginia Inspection Station and was cited for significant rust holes in the frame which have to be repaired. The frame should not have such significant rust that it needs to be fixed or it will be a hazard on the road. Based on other litigation around Toyota fames from this period of time is seems that this is a systemic issue and should be made to provide a recall based on the safety risk that is present with a frame failure as noted in previous class-action lawsuits. The Brian Warner et al. v. Toyota Motor Sales, U.S.A., Inc., Class Action Settlement (UNITED STATES DISTRICT COURT FOR THE CENTRAL DISTRICT OF CALIFORNIA Case No. 2:15-cv-02171-FMO-FFM) is a perfect example of the risk to the public if this is not corrected.
We took our 2004 4Runner for annual vehicle inspection and the service provider told us the vehicle would not pass safety inspection due to the excessive rusting on the steel frame and the suspension of the vehicle. Welding and patchwork will not fix this issue. My husband depends on this vehicle to work. The attached pictures give a small window into the extent of the damage. There is no current recall for this vehicle and year, but similar Toyota trucks from the same time frame have been recalled for the same exact issue. The entire frame needs to be replaced or worst case scenario, the vehicle is no longer usable. Toyota needs to remedy this issue for their loyal customers immediately.
Entire frame of the vehicle is rotten with rust and holes. This vehicle has been inspected by McDaniel Toyota, Marion, OH 43302 and the damage was confirmed. I have been and must continue to drive this vehicle even though the dealership did not recommend it. No evidence of the extent of the rust and damage was not noticed until October 2023 when a strap on the gas tank came loose. Upon further inspection, he noticed the holes and rust all over the frame. Reported to Toyota because other 2004 Models were recalled for this issue. They were of no assistance.
The entire frame is rusted. It's been welded back together on 2 different occasions. The last time it happened I was pulling out of driveway and the vehicle cannot be steered at all. I live in east TN and should not have a rusted frame. This is not an isolated problem. This is a problem with the 4runners and should be recalled. There are literally 1,000's of 4runners with Rusty frames. I don't understand why this isn't being recalled. You can reach me at [redacted] or [redacted].
Suspension complaints in other 4Runner years
Frequently asked questions
How common are suspension problems on the 2004 Toyota 4Runner?
NHTSA has 113 complaints about the suspension of the 2004 Toyota 4Runner, 17% of the model year's 678 complaints. The component named most often is front (2 mentions).
Is there a recall for 2004 Toyota 4Runner suspension problems?
No. NHTSA lists no suspension recall for the 2004 Toyota 4Runner, though it has 2 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 2004 Toyota 4Runner suspension problems start?
Half of the complaints with a recorded mileage happened before about 138,000 miles, and 10% before 25,000 miles.
Is it dangerous?
Owners linked 2 crashes, 0 fires and 1 injury 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.