2004 model year · NHTSA recalls, manufacturer TSBs, and owner forum reports · Updated September 2026
2004 · All trims · All engines
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According to Au7o's research across NHTSA recalls, manufacturer TSBs, and owner forum reports, the 2004 Toyota 4Runner has 22 documented known issues, with 6 rated critical. The most serious are 1GR-FE V6 Head Gasket Failure with External Coolant Leak at Rear of Cylinder Head ($1,800-$4,000 repair), 2UZ-FE 4.7L V8 Timing Belt is an Interference Belt - Failure at Neglected 90k Interval Destroys the Engine ($600-$1,500 repair), ABS Actuator / Master Cylinder Assembly Failure Triggering ABS/VSC/TRAC Lights and Brake Pump Noise ($1,200-$3,000 repair), 4WD Transfer Case Actuator Seizure from Infrequent Use Preventing 4HI/4LO Engagement ($600-$2,200 repair), Brake Booster / Master Cylinder Internal Leak Causing Hard Pedal and Reduced Braking Assist ($1,200-$2,800 repair) and X-REAS Suspension Hydraulic Shock Leaks Leading to Harsh Ride and Expensive Replacement ($800-$2,500 repair). Across all issues with published estimates, repair costs range from $15 to $4,000. DIY maintenance guides at au7o.io.
EQUIPMENT:OTHER:LABELS
Gulf States Toyota, Inc. (GST) is recalling certain Toyota 2023 GR Supra, 2024 4 Runner, Corolla, Grand Highlander, Grand Highlander Hybrid, Land Cruiser Hybrid, Tacoma, Tacoma Hybrid, 2023-2024 BZ4X, Corolla Cross Hybrid, GR Corolla, GR86, Highlander, Highlander Hybrid, Prius, Prius Prime, Sequoia Hybrid, Tundra, Tundra Hybrid, Venza Hybrid, 2023-2025 Crown, and 2025 Camry Hybrid vehicles equipped with GST accessories. The load carrying capacity modification label may display inaccurate added weight values. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard number 110, "Tire Selection and Rims."
EQUIPMENT:OTHER:LABELS
Southeast Toyota Distributors, LLC (SET) is recalling certain 2023 Toyota 4Runner vehicles. The load carrying capacity modification label states the incorrect load carrying capacity, which can result in an overloaded vehicle. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard number 110, "Tire Selection and Rims."
EXTERIOR LIGHTING:HEADLIGHTS
Southeast Toyota Distributors, LLC (SET) is recalling certain 2022 Toyota 4Runner vehicles. The driver's side high beam may be inoperable after the installation of accessory fog lights. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard number 108, "Lamps, Reflective Devices, and Associated Equipment."
EQUIPMENT:OTHER:LABELS
Southeast Toyota Distributors, LLC (SET) is recalling certain 2020-2022 4Runner vehicles equipped with 20-inch Black Gunner Wheels. The load carrying capacity modification labels are incorrect. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard number 110, "Tire Selection and Rims."
EQUIPMENT:OTHER:LABELS
Gulf States Toyota, Inc. (GST) is recalling certain 2022 4Runner, Tacoma, Highlander, and Highlander Hybrid vehicles. The load carrying capacity modification labels may not be permanent and can fade, becoming illegible. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard number 110, "Tire Selection and Rims."
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According to Au7o's research across NHTSA recalls, manufacturer TSBs, and owner forum reports, the 2004 Toyota 4Runner has 22 documented issues. The most frequently reported are: 1GR-FE V6 Head Gasket Failure with External Coolant Leak at Rear of Cylinder Head, 2UZ-FE 4.7L V8 Timing Belt is an Interference Belt - Failure at Neglected 90k Interval Destroys the Engine, ABS Actuator / Master Cylinder Assembly Failure Triggering ABS/VSC/TRAC Lights and Brake Pump Noise. Of these, 6 are rated critical and should be addressed promptly.
The 2004 Toyota 4Runner has 22 known issues compiled from NHTSA recalls, manufacturer TSBs, and owner forum reports. 6 issues are rated critical: 1GR-FE V6 Head Gasket Failure with External Coolant Leak at Rear of Cylinder Head and 2UZ-FE 4.7L V8 Timing Belt is an Interference Belt - Failure at Neglected 90k Interval Destroys the Engine and ABS Actuator / Master Cylinder Assembly Failure Triggering ABS/VSC/TRAC Lights and Brake Pump Noise and 4WD Transfer Case Actuator Seizure from Infrequent Use Preventing 4HI/4LO Engagement and Brake Booster / Master Cylinder Internal Leak Causing Hard Pedal and Reduced Braking Assist and X-REAS Suspension Hydraulic Shock Leaks Leading to Harsh Ride and Expensive Replacement. Prospective buyers should inspect for these issues and factor potential repair costs into their purchase decision. Regular maintenance following the manufacturer's schedule helps prevent many common problems.
Repair costs for known Toyota 4Runner issues range from $0 to $4,000, depending on the specific problem and whether you choose DIY or professional repair. The most critical issue, 1GR-FE V6 Head Gasket Failure with External Coolant Leak at Rear of Cylinder Head, typically costs $1,800-$4,000 to repair. Au7o provides step-by-step DIY maintenance guides that can help reduce repair costs.
Early 4th-generation 4Runners with the 4.0L 1GR-FE V6 are known for head gasket failures, often presenting as an external coolant leak near the rear of the passenger-side cylinder head. Owners report gradual coolant loss, sweet smell, overheating risk, and misfires if the leak wo… Repairs typically run $1,800-$4,000. Severity: high.
The 4.7L V8 (2UZ-FE) in V8 4Runners uses a rubber timing belt, not a chain, on a 90,000-mile / ~7-10 year interval. The 2005+ VVT-i version is an interference engine, so a belt that snaps at speed lets pistons strike valves, causing severe and expensive internal damage. Many owne… Repairs typically run $600-$1,500. Severity: high.
On 4th-gen 4Runners the integrated ABS actuator/brake master cylinder assembly (with electric pump motor and accumulator) fails internally. The pump motor or accumulator wears out so the pump never reaches pressure and runs continuously; owners get simultaneous ABS, BRAKE, VSC an… Repairs typically run $1,200-$3,000. Severity: high.
A well-known 4Runner problem is the transfer case shift actuator sticking or seizing, especially on trucks that spend years in 2WD or full-time mode without regular 4WD cycling. Owners report flashing 4WD lights, inability to engage or disengage 4HI/4LO, and in some cases being s… Repairs typically run $600-$2,200. Severity: high.
Multiple 4th-generation 4Runner owners report the brake pedal becoming hard, requiring excessive effort to stop, often accompanied by ABS/VSC/TRAC warning lights and a buzzing or continuously running brake actuator. Toyota issued service information for brake booster pump/master… Repairs typically run $1,200-$2,800. Severity: high.
4th-generation 4Runners equipped with the optional X-REAS cross-linked shock system commonly develop leaking shocks or hydraulic line failures as mileage climbs. Owners notice a bouncy or harsh ride, fluid seepage at the shocks, and degraded handling, but the real pain point is c… Repairs typically run $800-$2,500. Severity: high.
A recurring owner complaint on 4th-generation 4Runners is an erratic or inaccurate fuel gauge, often reading empty when fuel remains or failing to move smoothly after fill-ups. The usual cause is wear or contamination in the fuel level sending unit inside the tank, though wiring… Repairs typically run $350-$900. Severity: medium.
3rd- and 4th-gen 4Runners commonly develop power-steering whine and reddish ATF leaks with age. A whine is often not the pump itself but old fluid or a clogged filter screen in the bottom of the PS reservoir; leaks frequently originate at the union-bolt gaskets, high-pressure/ret… Repairs typically run $20-$500. Severity: medium.
Later 3rd-gen and 4th-gen 4Runners use a wide-band Air-Fuel Ratio (A/F) sensor as the upstream (Bank 1 Sensor 1) oxygen sensor. With age and heat cycling the sensor's internal heater or element degrades, setting codes such as P0125 (insufficient coolant temp for closed loop / A-F… Repairs typically run $120-$400. Severity: medium.
High-mileage 4th-gen 4Runners commonly develop front wheel-bearing wear, producing a humming or roaring noise that grows with vehicle speed and changes as the truck loads/unloads a wheel in turns. Off-road use, water/mud intrusion, and heavy tires accelerate it. Left unaddressed… Repairs typically run $100-$600. Severity: medium.
4th-gen 4Runner instrument clusters use small stepper motors to drive each gauge needle, and these motors fail with age — most often the speedometer, sometimes the tach, fuel, or temp gauges. Symptoms range from a needle stuck at a false reading (e.g., speedo frozen at ~40 mph) t… Repairs typically run $40-$400. Severity: medium.
The signature rear tailgate power glass on the 4Runner is a high-failure, high-search item. The window stops rolling up or down, rolls part way and falls back, moves slowly/unevenly, or makes grinding noises. Root causes are a worn rear window regulator/motor sub-assembly, a fail… Repairs typically run $120-$500. Severity: medium.
The accessory-drive belt tensioner and idler pulley bearings (a 6203-size sealed bearing) wear out and get noisy on the 1GR-FE, producing a persistent squeal/squeak/grinding from the front of the engine that is often mistaken for the water pump or a glazed belt. A weak tensioner… Repairs typically run $40-$350. Severity: medium.
The 1GR-FE develops a slow oil seep/leak at the front of the engine where the Bank 1 (passenger-side) cylinder head, engine block, and timing cover all meet. Toyota acknowledged it in TSB EG007-07 for 2003-2007 4Runners, and the leak persists on later 1GR-FE trucks. A secondary l… Repairs typically run $150-$1,500. Severity: medium.
As 4Runners accumulate miles, the catalytic converter loses efficiency and the ECU sets P0420 (Bank 1) and/or P0430 (Bank 2) when the downstream O2 sensor starts to mirror the upstream sensor. On the 4th-gen 1GR-FE, the primary cats are integrated into the exhaust manifolds, whic… Repairs typically run $150-$2,500. Severity: medium.
The 2UZ-FE V8 in 4th-generation 4Runners is known for exhaust manifold cracking, especially as the vehicle ages and heat cycles accumulate. Owners usually hear a cold-start ticking or tapping from the engine bay that quiets somewhat as the manifolds warm up, and some eventually g… Repairs typically run $700-$2,200. Severity: medium.
On higher-mileage 4Runner automatics owners report harsh/abrupt shifts, jerky 3-2 downshifts, unstable RPM blips while coasting near 40 mph, and delayed engagement. The most common mechanical cause is valve-body pressure control wear - a sticking pressure-regulator or throttle va… Repairs typically run $150-$1,500. Severity: medium.
The HVAC air-mix (blend) door servo actuators use plastic internal gears that strip over time. When a gear tooth breaks the servo loses calibration and produces a repetitive clicking/ticking sound behind the glove box or center dash, and the climate system can no longer regulate… Repairs typically run $60-$350. Severity: low.
The sunroof tray has plastic drain tubes at each corner that route water down the A-pillars (front) and into the rear pillars, exiting near the rockers. Leaves and debris clog these tubes, so water backs up in the tray and overflows into the headliner, down the A-pillar, and onto… Repairs typically run $0-$200. Severity: low.
A classic 4th-gen 4Runner HVAC complaint: the heater/AC blower works only on the highest fan speed and does nothing on the lower settings. High bypasses the resistor, so its continued operation while low speeds are dead is the tell-tale sign of a failed blower motor resistor (a s… Repairs typically run $20-$200. Severity: low.
Content on this page was compiled with AI assistance using NHTSA complaints, TSBs, owner reports, and public automotive data. While we strive for accuracy, this information may contain errors. Always verify repair procedures and specifications with your vehicle's service manual or a qualified mechanic.
