2004 Toyota 4Runner service brakes problems

“UNKNOWN: Excessive frame rust. frame is excessively rusting to the point where the brakes and suspensions is connected to the frame has been compromised. brake lines rusted to the point of failure, thus almost causing a wreck. Vehicle is now parked due to safety concerns involving the excessive rusting that is happening to the frame and any components that is attached to the frame.”

“Unknown: we were on [XXX] when the car went out of control. It first spun one way and then the other way and then we hit the concrete abutment where the guardrail connects to it. We hit it head on. It was as if we were on ice or oil, unable to gain control or brake. We checked the road and it was dry. Other cars were going by with no problem. The airbags didn’t deploy.”

“I bought my 2004 Toyota 4runner Sport edition as a new car, and have been the sole owner of the vehicle. I have taken good care of it the entire time. Regular car washes, service maintenance and necessary repairs over time. I recently had my 4runner in for repairs and spent a considerable amount of money, over $6,000 in anticipation of driving it for many more years. Following the repairs I was told by the mechanic that the frame was EXTREMELY rusted and that the entire frame would need to be replaced. There are large holes rusted through in many areas of the frame and a tremendous amount of rust over the entire frame. Rusted Pieces of the frame have fallen off. I fear for the safety of my family and me if I were to drive the vehicle at all. I have barely driven it since learning of the dangerous condition of the frame. I've limited any driving at all to my immediate area, and have driven very carefully and slowly, as I am extremely concerned that there might be a catastrophic failure of the frame while driving and I may be injured or killed, or worse....the vehicle might cause harm or death to another person. I am now basically without a vehicle and have been…”

“Seized front right brake caliper caused vehicle to slide off road during sudden stop to avoid debris in roadway. Took vehicle to a brake shop and they found that right front wheel was locked. This is the third time I have had the EXACT same problem with the brake system. The previous times, the problem occurred during nice weather and with windows open I smelled the burning brake pads and was able to get the problem fixed before it became a hazard. On the first previous incident, the repair required replacement of both front brake caliper, rotors, and pads. On the second previous occasion less than 20,000 miles ago BOTH front and rear calipers, rotors and pads were replaced. This is apparently a known defect in the 2004 Toyota 4Runner, yet Toyota has not conducted a recall to fix an extremely dangerous and ongoing problem. NOTE: I originally purchased the vehicle in New Jersey in 2004 and a Virginia Toyota dealer (Koons Toyota) worked on the brake system multiple times (2005-2006) and finally replaced the entire system.”

“OUR 2004 TOYOTA FORERUNNER WITH V6 ENGINE WAS PURCHASED AS A USED VEHICLE IN 2019 WITH 106,000 MILES ON IT. SINCE THEN, IT HAS DEVELOPED MORE AND MORE AREAS OF RUST ON THE FRAME DESPITE OUR EFFORTS TO MITIGATE THIS ISSUE. WE HAVE HAD TO REPAIR THE FRAME, SUSPENSION, BRAKES, AND WHEEL BEARINGS. WE CONTINUOUSLY INSPECT THE UNDERCARRIAGE AND CONTINUE TO DISCOVER MORE AND MORE AREAS OF SIGNIFICANT RUST/DETERIORATION DESPITE EFFORTS TO CLEAN, TREAT (WITH PAINT, RUST INHIBITORS, WELDING REPAIRS). WE ARE CONCERNED THAT THIS DETERIORATION WILL SOON RESULT IN A CATASTROPHIC FAILURE AND POSSIBLE ACCIDENT RESULTING IN PROPERTY DAMAGE, INJURY, OR DEATH.”

“TRUCK HAS BEEN WELL CARED FOR AND HAS 330K MILES ON IT. ALWAYS CLEAN AND MAINTAINED PROPERLY BY MYSELF AND PREVIOUS OWNERS. FRAME IS SHOWING SIGNS OF EXCESSIVE RUST IN THE FRONT BETWEEN THE WHEELS AND AT ALMOST ALL OF THE WELDED AREAS. SOME AREAS OF FRAME ARE COMING OFF IN CHUNKS AS IT APPEARS TO BE ROTTING FROM THE INSIDE OUT. THIS IS ALSO AFFECTING FUEL/BRAKE LIKES AS WELL AS SUSPENSION COMPONENTS. PICTURES CAN BE SENT UPON REQUEST. FAMILY HAS THE CAR AT THE MOMENT. *TR”