1. Welcome to 4Runners.com!

    You are currently viewing as a guest! To get full-access, you need to register for a FREE account.

    As a registered member, you’ll be able to:
    • Participate in all 4Runner discussion topics
    • Transfer over your build thread from a different forum to this one
    • Communicate privately with other 4Runner owners from around the world
    • Post your own photos in our Members Gallery
    • Access all special features of the site

2005 Rusted Out Frame

Discussion in '4th Gen 4Runners (2003-2009)' started by Bostonaustin, Feb 19, 2016.

  1. Feb 19, 2016 at 6:41 PM
    #1
    Bostonaustin

    Bostonaustin [OP] New Member

    Joined:
    Feb 19, 2016
    Member:
    #1588
    Messages:
    1
    Gender:
    Female
    Vehicle:
    2005 Black 4Runner
    None
    Hello

    Our 2005 4-Runner has awful rust issues. The entire frame is rusted and with only 40,000 miles on it, it is not able to be driven. Has anyone else had these issues?! Is there anything that can be done? Yes, we have contacted Toyota, and they have offered us $1000 towards a new car. Ya,, thanks!!
     
  2. Feb 19, 2016 at 7:41 PM
    #2
    Ol'Blue

    Ol'Blue Moderator Staff Member

    Joined:
    Apr 12, 2014
    Member:
    #55
    Messages:
    1,376
    Gender:
    Male
    "Not all who wander are lost"
    Vehicle:
    99 T4R LTD- 33's and locked, 01 SR5-,SAS Sold...
    A few things here and there. Still dreaming up stuff
    Lol a grand are you kidding me.

    Here is the deal. You live in the north east. You have crap winters and they know that. This could have be headed off with good maint. To the frame over that last ten years. Both of my 4runners are over 15 now and I li e in the mid west. Both the frames a rock solid because they were taken care of. I'm not try to be Debbie downer but that's the reality of it.

    Toyota had to replace the frames in the tacoma because of this but not the 4runners that I know of yet anyhow.

    Post some pics so we can all see how bad it really is that might help us better under stand also. We're is it at. Is it by critical point etc.

    Welcome to the site by the way...
     
    WallyT4R likes this.
  3. Feb 21, 2016 at 6:23 AM
    #3
    wnelax04sr5

    wnelax04sr5 Moderator Staff Member

    Joined:
    Apr 6, 2014
    Member:
    #12
    Messages:
    2,566
    Gender:
    Male
    First Name:
    Ethan
    CT
    Vehicle:
    2004 SR5 4X4 Galactic Gray
    Rarely is it that severe with such low miles. I've got 142k and theyve all been in NY or NE and I have almost no rust on my frame. 1k is an insult though
     
  4. Mar 21, 2016 at 2:44 PM
    #4
    Madmanmarty

    Madmanmarty New Member

    Joined:
    Jun 2, 2015
    Member:
    #664
    Messages:
    4
    Gender:
    Male
    Boston,there is a company in New England that specializes in clean-up and paint of rusted trucks.
    I can't think of their name but they are in ct,ri,or ma.
     
  5. May 25, 2016 at 11:48 PM
    #5
    CHawks_12

    CHawks_12 New Member

    Joined:
    Feb 28, 2016
    Member:
    #1641
    Messages:
    24
    Gender:
    Male
    Vehicle:
    2007 4Runner SR5 V8 Driftwood Pearl
    My sister-in-law got her Tacoma frame replaced for free by Toyota cause hers rusted out. It was an older Tacoma too.
     
  6. May 26, 2016 at 2:52 AM
    #6
    Tedmaywin

    Tedmaywin New Member

    Joined:
    Jun 15, 2015
    Member:
    #710
    Messages:
    8
    Gender:
    Male
    First Name:
    Ted
    Vehicle:
    2006 Limited
    Your rust situation is really nothing. Coming from someone who has restored 4 Austin Healeys over the years. In fact less than on my New England 2006 Limited. My only "unusual " repair in 165,000 miles of personal ownership since new, a rusting out radiator. That area takes a lot of crap around here. Even frequent underbody washes are almost useless here, but once the chloride goes down, it just hangs around until May !
     
  7. May 29, 2016 at 5:52 AM
    #7
    LCBJR77

    LCBJR77 New Member

    Joined:
    May 26, 2016
    Member:
    #2067
    Messages:
    18
    Gender:
    Male
    First Name:
    Larry
    Connecticut
    Vehicle:
    2007 4runner Limited 4.0 (Driftwood Pearl)
    Xenondepot 4000k Philips bulbs swap, Weathertech Mats/ front & back
    The guy I bought my 4runner from just had his frame replaced on his 2001 Tacoma

     
  8. Mar 14, 2017 at 9:51 AM
    #8
    HMOSS

    HMOSS New Member

    Joined:
    Mar 14, 2017
    Member:
    #3697
    Messages:
    1
    Gender:
    Male
    First Name:
    Howard
    Vehicle:
    2005 4RUNNER
    None
    I am the original owner of a 2005 4RUNNER Limited. My vehicle has only 61,500 miles registered on the odometer...This SUV has never been involved in any accident. I just noticed the frame has severe corrosion...The safety and integrity of the vehicle and its passengers has been compromised by the severe deterioration of the chassis. I have notified Toyota of the condition and requested their inspection of my vehicle...Hoping Toyota will remedy this mater...If not, I'll pursue other means for a resolution.

    P3200948.jpg
    P3200951.jpg
    P3200952.jpg
     
    BananaCooler likes this.
  9. Mar 28, 2018 at 7:44 AM
    #9
    ct671

    ct671 New Member

    Joined:
    Mar 28, 2018
    Member:
    #5731
    Messages:
    1
    I have an 05 with the same rust issue on the support below the radiator. What ever happened with your request to Toyota?
     
    BananaCooler likes this.
  10. Jan 3, 2019 at 2:31 PM
    #10
    BawanaDave

    BawanaDave New Member

    Joined:
    Jan 3, 2019
    Member:
    #8318
    Messages:
    3
    Gender:
    Male
    First Name:
    David
    Vehicle:
    2004 4 Runner
    I have an 04 4 Runner. Live in Virginia, so our winters are not bad. The frame is rusted so bad that it failed inspection today. I know a bit about welding and this is not repairable short of swapping out the frame.. odometer just clicked over 100K. Thanks Toyota.
    Before anyone starts telling me it is due to poor maintenance, I have owned vehicles for 45 years. I have never seen anything like this. It appears to be rusting from the inside out. I’m not talking surface rust. It is coming off in chunks.
    Guess I’ll be joining the Jeep forum, because I’ll never buy another Toyota if the company doesn’t stand behind this.
     
  11. Jan 3, 2019 at 3:55 PM
    #11
    jdevtac

    jdevtac New Member

    Joined:
    Oct 17, 2017
    Member:
    #4904
    Messages:
    12
    Gender:
    Male
    Vehicle:
    02 4Runner SR5 2WD
    There is currently a NHTSA investigation that started back in August but I wouldn’t get my hopes up, and I doubt it will be a timely investigation either.

    Jeep was no better at one point in time. They are practically the reason why frame reinforcement caps were made.
     
  12. Jan 4, 2019 at 9:41 AM
    #12
    DGP1961

    DGP1961 New Member

    Joined:
    Sep 17, 2018
    Member:
    #7154
    Messages:
    298
    Gender:
    Male
    Vehicle:
    2018 SR5 Premium
    I totally agree it's 2019 it's totally unacceptable to be expected (or for the mfg to expect) owners to get on their backs and spray their frames with rust inhibiter! O.K. I get some people do and great for them but surely 95% of the driving population doesn't do it including me. In 5 or 6 years my 2018 SR5 will be gone I'll just trade it in and avoid the issues. Had the vehicle five months now and from what I've seen I'll be perfectly fine letting it go when it's time I'm obviously not so overly impressed with it as other hard-core owners are. For the money spent I'm reading about to much $hit about them.
     
  13. Jan 4, 2019 at 10:21 AM
    #13
    BawanaDave

    BawanaDave New Member

    Joined:
    Jan 3, 2019
    Member:
    #8318
    Messages:
    3
    Gender:
    Male
    First Name:
    David
    Vehicle:
    2004 4 Runner
    Regarding this frame rust problem. I just got off the phone with Toyota Customer Service. The customer service agent said that they do not follow forums on the Internet. They do take this seriously and that everyone who is experiencing this problem should call Toyota and they will issue you a case number. If they get enough complaints, they might issue a voluntary service repair. At least you have put them on notice of this safety hazard.
    I’m not holding my breath, but I am pissed.
    Side bar. There is a shop near me in VA that is completely aware of the problem and offers to weld reinforcing metal to the frame (if possible) then coat the entire frame to prevent further damage. Cost about $1,000. As stated in previous post, I know a bit about welding and doubt this is possible on my 4 Runner.
     
  14. Feb 5, 2019 at 9:47 AM
    #14
    HoBoDanny

    HoBoDanny That Dude

    Joined:
    Feb 5, 2019
    Member:
    #8697
    Messages:
    228
    Gender:
    Male
    First Name:
    Daniel
    Kentucky
    Vehicle:
    2004 SR5 V6 4WD 4Runner
    Hankook DynaPro ATM RF10 265 70R17 113T Tires TPMS Bypass Mod Hydrocarbon Filter Removed Merca decal
    I still don’t understand how Tacoma’s get frame recalls and 4Runners don’t. Is there a reason behind this? Were the frames made by different companies?
     
  15. Feb 5, 2019 at 9:54 AM
    #15
    jdevtac

    jdevtac New Member

    Joined:
    Oct 17, 2017
    Member:
    #4904
    Messages:
    12
    Gender:
    Male
    Vehicle:
    02 4Runner SR5 2WD
    4runner frames were made in Japan. As opposed to all the recall frames made or coated by Dana.

    I think the issue with the 4runner frame isn’t so much the strength or quality of coating but rather the allowed collection of fluids in places that lead to accelerated rust, when if adequate drainage was provided, this probably wouldn’t be a problem. Namely, rear trailing arm mount area and the front auxiliary rad bracket that the trans cooler lines and skid plate mount to. Compounding living in a salty environment only makes it 100x worse.
     
  16. Feb 5, 2019 at 10:25 AM
    #16
    HoBoDanny

    HoBoDanny That Dude

    Joined:
    Feb 5, 2019
    Member:
    #8697
    Messages:
    228
    Gender:
    Male
    First Name:
    Daniel
    Kentucky
    Vehicle:
    2004 SR5 V6 4WD 4Runner
    Hankook DynaPro ATM RF10 265 70R17 113T Tires TPMS Bypass Mod Hydrocarbon Filter Removed Merca decal
    That makes sense. I have noticed the only serious rust on mine is on the lower radiator bracket where the skid plate mounts. I’m guessing since quality wasn’t a problem Toyota doesn’t want to own up to a design flaw.
     
  17. Feb 5, 2019 at 11:37 AM
    #17
    jdevtac

    jdevtac New Member

    Joined:
    Oct 17, 2017
    Member:
    #4904
    Messages:
    12
    Gender:
    Male
    Vehicle:
    02 4Runner SR5 2WD
    Like I posted above, there is a current open NHTSA investigation into the rust matter, but I’m not holding my breath.
     
    HoBoDanny likes this.
  18. Feb 5, 2019 at 2:53 PM
    #18
    BawanaDave

    BawanaDave New Member

    Joined:
    Jan 3, 2019
    Member:
    #8318
    Messages:
    3
    Gender:
    Male
    First Name:
    David
    Vehicle:
    2004 4 Runner
    JDEVTAC’s response is the one that makes the most sense. As I stated, my 4Runner appears to be rusting from the inside out. So holding water would explain this. Maybe weep holes would have prevented this problem. I suspected that they sprayed the frames instead of dipping them in rust preventative.
    My 4RUNNER is at the frame repair shop now so I cannot go out and look at it, but I seem to remember some pretty severe rust on the upper parts of the frame where it goes over the rear axle. If this is the case, it might throw some water on this theory. Pun intended.
     
  19. Feb 6, 2019 at 9:43 AM
    #19
    DGP1961

    DGP1961 New Member

    Joined:
    Sep 17, 2018
    Member:
    #7154
    Messages:
    298
    Gender:
    Male
    Vehicle:
    2018 SR5 Premium
    Still say this is ridiculous and I personally refuse to go outside, lay on my back and spray the whole bottom with some goopy $hit or whatever it is. My god there has been inventions to stop or greatly slow rust it is 2019 isn't it. I've got an '18 but if and when it ever STARTS to look concerning I'm getting rid of it and will not buy another. Yeah I get "taking care of my stuff" and all my motorized tools look and run like their a month old (some 10+ yrs) so I don't buy that. ok rant over...
     

Products Discussed in

To Top