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 2005 Toyota 4Runner owners, lightly cleaned up (personal details are redacted by NHTSA).
The contact owns a 2005 Toyota 4Runner. The contact stated that while driving at an undisclosed speed, the vehicle briefly hesitated and was unable to accelerate, prompting the contact to discontinue driving the vehicle. The check engine warning light was illuminated. The vehicle was taken to an independent mechanic, who diagnosed a failure with the catalytic converter. The contact was also made aware that the mechanic discovered excessive corrosion covering the entire subframe of the vehicle. The contact was advised not to drive the vehicle. The vehicle was not repaired. The manufacturer was notified of the failure but provided no assistance. The failure mileage was 205,000.
The contact owns a 2005 Toyota 4Runner. The contact stated that the subframe was rusted. The TPMS warning light was illuminated. The vehicle was taken to an independent mechanic, who repaired the TPMS, but the failure persisted. The vehicle was taken to the local dealer, where it was diagnosed that the frame was rusted and recommended that the vehicle no longer be driven. The mechanic referred the contact to the manufacturer. The vehicle was not repaired. The manufacturer was contacted and referred the contact to the NHTSA Hotline. The failure mileage was approximately 200,948.
The contact owns a 2005 Toyota 4Runner. The contact stated while the vehicle was at the independent mechanic for servicing, and he was informed that the sub frame was severely corroded. The dealer was notified of the failure and referred the contact to the manufacturer. The manufacturer was notified of the failure and referred the contact to the NHTSA Hotline for assistance. The vehicle was not repaired. The failure mileage was approximately 166,000.
The contact owns a 2005 Toyota 4Runner. The contact stated that after purchasing the vehicle, it was discovered that the subframe of the vehicle was severely rusted. The cause of the failure was not determined. The manufacturer and local dealer were notified of the failure. The failure mileage was 212,000.
When I first saw the pictures on the internet, I noticed that the front underside appeared to have rust issues. (Frontal shot) I contacted that sales person and he blew me off when I requested photos of the underbody. After several attempts, he finally sent a couple of pictures. The pictures obviously did not show the major rust issues as I have provided. The pictures were carefully fabricated not to show the major rust issues. It was apparent that the vehicle was taken off the internet while they hid the rusty underbody by applying some coating. A short time later, the dealership reposted the vehicle on their website. The vehicle was not properly advertised as having this major rust issue. I asked the salesman if his family was driving the vehicle, would he feel safe. He replied, "Absolutely". With this said, I decided to purchase the vehicle. Also, my signature is not on the "We owe". …
- The undercarriage and frame have had premature rusting for years. The car is otherwise in excellent condition due to my care of it over the last 20 years. 5 years ago, a service person at my local Toyota dealership said, "I'm really disappointed in Toyota, I've never seen rust like this." I have now recently been told by a local service shop that it's time to get a new car. The lines are all corroded for the power steering, etc, and he was unable to even "touch them," and said that the rust issue is no longer safe, and we shouldn't drive far from home. - We are now unable to drive the car much, as we live in the country and have far communities. With a [redacted] , we are unwilling to drive the car over 45 mph, or more than 10 miles for fear of an accident after reading about the manufacturing defect in this model of the 4-Runner. …
I have a 2005 Toyota 4runner with frame rust that has caused everything under my 4runner to rust. Toyota knows these frames have problems with rust and corrosion and have done nothing, I am far from being the only one with this complaint or problem. It is up for inspection anytime. I have taken it to get work done at shops and been turned away because of the amount of rust on all bolts, lines, all metal under truck causing it to be a liability. I cant even get my skid plates off to fully address the issue. The metal is starting to split on the main frame by the tire, it is rotting from inside. Rust has always been there but last couple years has gotten really bad. So much rust my gas tank strap has broken but so much rust I cant get the skid plate off to fix it.
My frame has rotted through, causing the rear bump stops to fall off, putting excessive wear on both frame and suspension components. In parts of the frame, it has rotted all the way around and caused a loss in structural integrity. Worst of all, there is a hole near the rear most strap holding the gas tank to the chassis, which is a risk to not only me and my pregnant wife but others driving on the road around me if it where to fall off. Looking at the body, there is no rust or corrosion. The same goes for the engine bay, the rust is entirely located on the frame. Mechanically, the vehicle is in excellent shape. It has now got to the point it will no longer pass a NYS inspection.
I would like to complain regarding my 2005 4Runner. Went to have the fluid changed at a dealership in the early part of July 2021 and they could not perform the service due to excessive underbody rust and corrosion . Therefore the I will have to find a service that can remove the corrosion to be able to have the shocks change, differential fluid change and to check and perform service on the brakes. The corrosion is starting to eat at the key components of the vehicle to the point where I may not be able to drive. Steering will be restricted and brakes will malfunction if they cannot get to the remove the areas to service the vehicle.
Frame of the vehicle is rusting from the inside out. Upon inspection, holes in the frame are found, with many more hidden from sight. This is a disaster waiting to happen. This puts the driver and anyone else on the road at extreme risk if the frame breaks while driving. This problem is well documented with Toyota, and they have previously replaced Tacoma, Sequoia, and Tundra frames, but not 4runners. Everyone is at risk with these frames, even if it does not appear so. My frame looked solid until I began hitting it with a hammer and screwdriver and breaking away very weak spots of metal.
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 2005 Toyota 4Runner?
NHTSA has 185 complaints about the body & structure of the 2005 Toyota 4Runner, 44% of the model year's 425 complaints. The component named most often is body (163 mentions).
Is there a recall for 2005 Toyota 4Runner body problems?
No. NHTSA lists no body & structure recall for the 2005 Toyota 4Runner, though it has 5 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 2005 Toyota 4Runner body problems start?
Half of the complaints with a recorded mileage happened before about 129,000 miles, and 3% before 25,000 miles.
Is it dangerous?
Owners linked 3 crashes, 0 fires and 2 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.