Toyota 4Runner 2005 — Reported problems

Head gasket failure. 2005 toyota 4runner generation are notorious for head gasket failure. Due to the poor manufacturing of the gasket it has been deteriorating and has allowed coolant to leak into the cylinder causing misfires and possibly more damage internally. including permanent mechanical breakdown or a completely ruined engine block. High risk of Hydrolock, Damaged Engine Bearings and Sludge, Severe Overheating, Catalytic Converter Failure. Any of these effects cause by this head gasket failure will be extremely dangerous to happen while driving. The vehicles is being taken to a independent mechanic 09/28/2026 for conformation diagnosis. And possible repairs. The check engine light showed the following code-P0300, P0302, P0304. The only symptom where misfiring and coolant levels depleting. The vehicle has not been inspected by the manufacturer, police nor insurance representative. Noticeable misfiring around the beginning of 2025 has just became more aggressive since 2026

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.

Odometer Fraud. The contact purchased a 2005 Toyota 4Runner. It was discovered that there was a mileage discrepancy. The vehicle was a private sale. At the time of purchase, the vehicle mileage was 217,000, and at the time of registration, it was discovered that the mileage was 342,912.

Premature/unsafe frame rot

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 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 [XXX] , 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. - It has not been inspected by the above stated people. - no warnings, I would not have know the vehicle had such severe premature rusting issues if it weren't for a service person telling me such. -My vehicle has under 140k miles on it, and I've taken exceptional care of it over the past 20 years. I could have sold it for 10k given its condition, and low mileage, but it is now likely worth nothing given the manufacturing defect which caused premature rusting. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

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". Also, the vehicle has an exhaust leak from the manifold area. It makes a loud ticking noise. This is going to cost approximately $1,500 to fix. The air conditioner is not blowing cold and either has a leak or in need of freon. This is another repair out of my pocket. This is what kind of pre-owned vehicle they sold me. This vehicle should have never been listed for sale.

ENTIRE body frame has excessive rust, holes, and cracks. It is available for inspection. Toyota dealership says it is safe to drive for now but it is failing. I feel any cracks, rust, holes, separation of frame components places all occupants and anyone near the vehicle at risk for when anything fails - this could be when the vehicle is on the expressway in motion (such as when the GM ignition switch failures happened), causing catastrophic loss of life, injuries, and damage to all. It's not a matter of "if" it happens, it's "when" it will happen. There are no warning lamps, messages, or other symptoms of the problem. The exterior, interior, braking, engine of the vehicle are in remarkable shape so it's very misleading. There are also 4runners on dealership lots that have significant rust, holes, and cracks in the frames that the dealership does not warn about, rather, they still have high for-sale values because the vehicle looks good otherwise.

Frame rot. The frame on the 4Runner is a known problem for excessive rot. My frame is shot. There is no reason a frame on a 2005 should be rotted. I was advised by my mechanic that my frame is dangerously close to snapping in half. This needs fixed by Toyota!

Under frame is rusted. The area between the doors in the passenger side is gone. only the top face of the member is present.

Frame has very severe rust and has started to come part in places. Soon vehicle will no longer be road worthy.

Rear hatch glass broke during defroster operation. Started to smell a burning smell and then moments later the entire rear hatch glass shattered. Known issue by Toyota. They issued a brief Warranty Enhancement Program (ZG7) in March 2017 thru April 2018 but are refusing to honor current issues.

Excessive frame rusting. There are holes in the frame from rusting. At this point in time there isn’t anything I can do about the issues. Frame is unrepairable.

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.

Frame of the vehicle is showing rust corrosion. The frame are the same as the tacomas that were released the same year. The tacomas were granted frame replacement by Toyota but 4Runners weren’t. Noticed a lot of other 4th generation 4Runners are having the same issues.

The rear window shattered while using the rear window defrost.

Frame has rusted through and the boot of the frame that holds the front driver side suspension is 3/4 of the way cracked. Independent Body shop rendered car unsafe to drive.

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 rear windshield shattered suddenly without any apparent reason. At first I thought something had smashed onto our car because there was a loud smashing sound as it a sheet of ice fell on the roof of the car, but it was not a snowy or icy day and there was no rock or branch by the car. It was rainy and cold and I had the wipers and defroster on so the only thing I could think of as the problem was the temperature of the glass and defroster caused the glass to shatter. I had all three of my children in the car (all under 6 years of age) in the backseat and I was lucky none of the shattered glass projected into the air on to them. The entire windshield was shattered.

The contact owns a 2005 Toyota 4Runner. The contact stated that while her brother-in-law was inspecting the vehicle battery, he activated the rear windshield defroster and the rear windshield exploded. There were no injuries sustained. The vehicle was taken to an auto glass repair mechanic, where it was diagnosed that the defroster motor and the rear windshield wiring had melted. The auto glass repair mechanic replaced the rear windshield and referred the contact to the dealer for the defroster motor replacement. The dealer was not notified of the failure. The vehicle was not repaired. The manufacturer was made aware of the failure and informed the contact that there was no recall associated with the VIN. The failure mileage was approximately 170,000.

Frame on 2005 Toyota 4Runner has excessive rust due to Toyota’s negligence on frame production. I can make it available if needed. My safety is 100% compromised, had my mechanic not have told me of the issue, I would have kept driving the vehicle and the suspension could have detached from the frame at any point. The problem has been confirmed by my independent service center South Lake Automotive. It has not been inspected by police, manufacturer or other. There was no warning prior to the failure. Had I not had it pointed out as an issue, I would never have known it was an issue.

The frame and complete undercarriage is completely prematurely rusted.

The frame on both sides of the vehicle in the front, where it connects under the radiator crossbar has rusted through.Not feeling to safe about this. also the transmission cooling lines are also looking thin. The dealership I have maint. done at informed me of this condition. Can send pictures if needed.

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 was driving my 4Runner and the rear glass exploded and shattered. This is a known issue with Toyota and documented in T-SB-0189-17 and warranty enhancement ZG7. There were no warning lamps, messages or other symptoms of the problem prior to the glass shattering. Toyota refuses to cover the repair costs and the estimate provided by the dealer is $1,200. Photos were taken in my garage when I got home immediately after the explosion occurred.

Upon moving with the flow of traffic at about 30 to 35 mph a car shot from a driveway straight in front of me causing me to hit that driver in the rear quarter panel of the passenger side putting him into a 360 spin not causing my airbags to deploy at that rate of speed in my opinion that is a huge fault of my system from my vehicle at that rate of speed my airbags should have went off to protect me as if I didn't have my seat belt on but thank God I always wear my seatbelt

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.

I took my vehicle into the Toyota Dealer after mechanic told my frame was rusting. The dealership confirm the frame is rusted. The frame of the vehicle should not be rusting out.

The entire frame is rusted to the point the vehicle is unsafe to operate on the road. Parts of the vehicle could potentially break off because they have rusted through causing the vehicle to be involved in an accident. The vehicle has been inspected by an independent service center and a authorized dealer who confirmed the vehicle is unsafe to drive on the road because of the rust on the frame, differential, and crossmember. There was not any warning lights a mechanic mentioned it to me a in February/March when they were changing the oil that the frame would not last much longer.

I own a 2005 Toyota four runner. The frame under the truck is completely rusted out everywhere. The car started swaying and I felt as though my vehicle was going to go out from under me. It felt like it was collapsing or melting underneath. This is my family vehicle. It was a dangerous situation and my entire family was in the vehicle. My spouse a children. I took it to a independent shop. The mechanic said that the frame had rusted out under the Toyota. He told me to park it and not drive it because it was about to split apart. He said that we were very lucky and just moments from a catastrophe. He also told me that their had already been a recall and replacement of the malfunctioning frames on Toyota Sequoia, Tacoma and tundra. In his professional option he thought Toyota should do the same type recall for the rusted out frame problem on the four runner. You are the first and only person I have reported this to. I will wait for your response and next steps: [XXX] Cell number [XXX] Home number [XXX] [XXX] INFORMATION Redacted PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6).

The rear control arm broke while I was driving causing me to swerve uncontrollably and almost causing a collision

The back brake lines rusted out completely crumbling causing me to almost collide head on with oncoming traffic while my kids where in the car. This was a terrifying experience. Upon further inspection the back brakes were so rusted out that they crumbled to dirt.

I have a 2005 4Runner with significantly rusted out frame that makes me worried about safety of driving it. I feel the amount of corrosion present is way beyond what I would expect for that year of vehicle

When accelerating it feels like the frame shifts on the body lots of rust,, as well as the power steering was a little low I added power steering fluid next thing you know it stopped working and driver seats is falling apart and collapse in Woodson within itself as well as the airbags didn't go off upon rear-ending a vehicle they came to a sudden stop in front of me at least 25 miles per hour

Rear window shattered moments after using the defroster at a stop light

The frame broke loose from the rear sway bar due to excessive rust while I was driving it. My 4Runner is an 05 and has the same frame as the Tacomas of the same year, except with no recall. I believe it is wrong to recall the Tacoma frame and not the same 4Runner frame. It is available for inspection. The car wanted to loose control anytime the accelerator was pressed or released. The problem has been an issue for many 4Runner owners of similar years. There was no warning to this occurrence.

My 2005 4Runner frame is completed covered in rust and is corroding. Several places on the frame is rotting away.

Extreme rusting on frame and all parts under the carriage. Vehicle suspension and all moving parts underneath could fail or fall apart causing major accident or death to me or other vehicle.

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.

Vehicle’s frame and suspension is showing major rust prematurely forming from the inside-out of the frame causing visible weakness in the structure of the frame that could cause engine or other suspension parts to fall off the frame of the car due to improper treatment of the frame. If I were to get in a car accident I don’t see the frame holding it’s structure. I would I highly suggest to have a safety recall done with frames with such damage.