Problems · by component

1996 Toyota 4Runner structure problems

42 owner complaints to NHTSA about the 1996 Toyota 4Runner cite structure, 25% of all 165 complaints for this model year.

Complaints
42
25% of all complaints
Crashes
2
Reported by owners
Fires
0
Reported by owners
Injuries
4
Reported by owners
01 —Owner reports

What owners say about the structure

Verbatim from NHTSA complaints, newest first
“MY 1996 TOYOTA 4RUNNER SUFFERS FROM EXCESSIVE RUST THAT CAUSED ME TO BE HAVE A HORRIBLE LOSS OF VEHICLE CONTROL DUE TO THE FRAME EXCESSIVELY CRACKING. THE CRACKING WAS DUE TO WHAT AN INDEPENDENT RESEARCH COMPANY STATING THAT THE RIGHT-REAR FRAME RAIL CRACKED AND SEPARATED FROM THE FRAME DUE TO EXCESSIVE RUSTING. THE INDEPENDENT RESEARCH COMPANY POINTED TO NUMEROUS KNOWN REPORTING'S ON THE INTERNET AS A COMMON OCCURRENCE OF THIS VEHICLE. I MADE A PERSONAL CALL TO TOYOTA CUSTOMER CARE AND WAS TOLD THAT THEY LOGGED MY COMPLAINT BUT THAT THEY WOULD NOT COVER ANY CLAIMS HEREIN TO HELP IN FIXING THE ISSUE. MY VEHICLE ONLY HAD APPROXIMATELY 137,000 MILES AT THE TIME OF THE INCIDENCE. THE OCCURRENCE HAPPENED WHEN I WAS TRAVELING ON AN INTERSTATE AT APPROXIMATELY 65 MILES PER HOUR. I CROSSED AN AREA THAT HAD STANDING WATER (NOT DEEP BY ANY MEANS MIND YOU) AND THE REAR END COMPLETELY SHIFTED OUT TO THE RIGHT OF ME AND CAUSED ME TO SPIN. THIS WATER WENT ACROSS ALL THREE LANES AND NO ONE ELSE EXPERIENCED ANYTHING LIKE I DID. THE VEHICLE COMPLETELY SPUN AROUND AND I ENDED UP IN THE EMERGENCY LANE FACING HEAD ON AT ONCOMING TRAFFIC. I WAS FORTUNATE THAT NO ONE WAS INJURED OR…”
Owner complaint to NHTSAFiled Aug 24, 2018StructureODI 11122229
“FRAME RUST, A FAIR AMOUNT OF RUST IS CAUSING CONCERN AND MAKES ME QUESTION HOW TRUSTWORTHY VEHICLE IS. THE DATE LISTED ISNT THE DATE OF THE INCIDENT ITS ROUGHLY AROUND THE TIME THE EXTENT OF THE RUST HAD BEEN NOTICED.”
Owner complaint to NHTSAFiled Jul 26, 2018Suspension, StructureODI 11113716
“FRAME IS RUSTING FROM INSIDE OUT. HOLES IN FRAME BIG ENOUGH TO PUSH YOUR WHOLE ARM THROUGH. AREAS OF FRAME CONNECTED TO SUSPENSION PREMATURELY RUSTING OUT. THIS REST OF THIS VEHICLE IS IN EXCELLENT CONDITION, BODY PANELS INCLUDED. WELDER TOLD ME ENTIRE FRAME IS RUSTING AWAY AND REPAIR TO THE FRAME IS VERY DIFFICULT ANF EXPENSIVE EVEN IF POSSIBLE. VEHICLE HAS UNDER 185,000 MILES AND RUNS GREAT. I HEAR CREAKING DEVELOPING AND AM AFRAID CAR MAY SPLIT IN HALF. WHY IS TOYOTA NOT STEPPING UP AFTER ADMITTING TO BADLY MANUFACTURED FRAMES.”
Owner complaint to NHTSAFiled Mar 31, 2018Suspension, StructureODI 11082258
“TAKATA RECALL I'M SUPER DISAPPOINTED IN THE RUST PROBLEM WITH TOYOTAS, I'VE OWNED NOW THREE TACOMAS, ALL RUSTED OUT, I RECENTLY GAVE UP AND TRIED BUYING A 1996 4RUNNER, GOT A REALLY GOOD DEAL ON IT, I CAN SEE WHY ANYWAYS I BOUGHT IT AND IT TURNS OUT THE WHOLE FRAME WAS COATED SO I COULDN'T SEE RUST, WITH FURTHER INSPECTION THERE'S A BIG CRACK IN THE FRAME FROM RUST, AND THE WHOLE FRAME IS RUSTED. THE CRACK IS RIGHT BESIDE THE EXHAUST, I CONTACTED TOYOTA AND THEY SAID BRING IT IN FOR INSPECTION AND THEY SAID IT WOULD NEED REPLACED, BUT WOULD COST 14-16 THOUSAND DOLLARS. THEN THEY CHARGED ME FOR THE INSPECTION 60 DOLLARS, WHEN THEY DIDN'T EVEN TELL ME I'D BE CHARGED. TOYOTA REALLY NEEDS TO STEP UP!!! FEEL FREE TO CALL ME AT [XXX] *TR”
Owner complaint to NHTSAFiled Aug 15, 2017StructureODI 11015313
“WHILE CORNERING IN CITY DRIVING I HEARD A CLUNKING NOISE AND INVESTIGATED WHEN I ARRIVED HOME. THE FRAME HAS CORROSION AT THE RIGHT REAR TRAILING ARM BRACKET. THE BRACKET WAS RUSTED AWAY FROM THE FRAME AT THE TOP BUT STILL ATTACHED AT THE BOTTOM. THE BRACKET AND FRAME WERE WELDED WITH ADDTIONAL METAL. I CHECKED THE REST OF THE FRAME AND NOTICED THERE IS ALSO A HOLE IN THE CROSSMEMBER BELOW THE DRIVERS SEAT AND OTHER LARGER RUSTED HOLES ALONG THE FRAME. THIS IS A MAJOR SAFETY CONCERN. I WILL HAVE TO TAKE IT TO A FRAME SHOP AS TOYOTA SAYS THERE IS NO RECALL ON THE 4RUNNER ONLY THE TACOMA AND TUNDRA. I KNOW MANY OTHER 3RD GENERATION 4RUNNER OWNERS WHO HAVE THE SAME PROBLEM. THE VEHICLE BODY HAS NO RUST OTHER THAN A SMALL SURFACE AREA AT THE DRIVERS DOOR ROCKER PANEL AND NEAR THE WINDSHIELD. THE VEHICLE IS VERY WELL MAINTAINED.”
Owner complaint to NHTSAFiled Jun 5, 2017StructureODI 10993315
“I OWN A 1996 TOYOTA 4RUNNER THAT HAS FRAME IS RUSTED WITH LARGE HOLES. IT HAS NOT CAUSED AN ACCIDENT YET BUT I BELIEVE THE MANUFACTURER SHOULD BE HELD ACCOUNTABLE. ESPECIALLY WHEN THE SAME COMPANY HAS REPLACED FRAMES AND BOUGHT BACK OTHER MODELS FOR THE EXACT SAME ISSUE. HOW AM I (AS A 4RUNNER OWNER) JUST OVERLOOKED AND BRUSHED ASIDE.”
Owner complaint to NHTSAFiled Dec 30, 2016StructureODI 10938869

Showing 6 of 42 reports. Read every report on NHTSA.gov.

Data from NHTSA Complaints API (owner reports, unverified) · synced Nov 10, 2026NHTSA vehicle page

Complaints are unverified owner reports to NHTSA and are not normalized for sales volume. One complaint can cite several components.

Other 1996 4Runner problem areas