2004 Toyota Sequoia Problems: 4 Issues Every Owner Should Know

2004 model year · 4,000+ owner reports · Updated May 2026

According to Au7o's analysis of 4,000+ owner reports, the 2004 Toyota Sequoia has 4 documented known issues, with 1 rated critical. The most serious is Frame Rust and Structural Corrosion ($200-$5,000 repair). The most commonly reported issue is Secondary Air Injection System Failure (2UZ-FE) with 2,400 owner reports. Across all issues, repair costs range from $30 to $5,000. DIY maintenance guides at au7o.io.

All 4 Known Issues

Community Reported

1,600 owners

On the 2001-2007 Toyota Sequoia, 1st-gen Sequoias in salt-belt states develop severe frame rust, particularly at the rear crossmember, leaf spring mounts, and spare tire carrier area. Toyota issued a Limited Service Campaign (LSC) for some Tundra frames but Sequoias were not included despite sharing the platform.

Common Symptoms

Visible rust on frame rails
Rear crossmember deterioration
Leaf spring mount cracking or separation
Spare tire carrier loose from rusted mounting
Failed safety inspection for frame condition

How to Fix

For surface rust: wire brush, treat with POR-15 or Eastwood Rust Encapsulator, and apply Fluid Film annually. For structural rust: professional frame repair with welded reinforcement plates or boxed sections. Severe cases may require frame replacement from a southern/western donor vehicle. Annual undercoating with Fluid Film or Woolwax is essential for prevention.

What Owners Are Using

Parts and tips from 1,600+ owners who fixed this issue

Tip
Tip
UpgradePOR-15 rust preventive coating stops rust permanently (POR-15 Rust Preventive Coating)
View on Amazon
UpgradeRust-Oleum rust converter spray for treating corroded panels (Rust-Oleum Rust Converter Spray)
View on Amazon

Typical repair cost:$200 - $5,000

Research This Issue

1,600+ owners have reported this issue

Google Reddit YouTube NHTSA

Community Reported

High Confidence1,600 reportsLast reported by owners Feb 2026Reviewed Feb 2026

On the 2001-2022 Toyota Sequoia, the gas-charged struts that hold the rear liftgate open on the Sequoia lose pressure over time, causing the heavy rear hatch to fall on its own. This is a safety concern as the liftgate is large and heavy enough to injure someone if it drops unexpectedly. The struts typically begin to weaken after 5-7 years and fail completely within 8-10 years. Cold weather accelerates the failure as gas pressure drops with temperature. Both first-generation (2001-2007) and second-generation (2008-2022) models are affected.

This issue also affects: Chevrolet Traverse, GMC Yukon XL, Toyota Matrix

Common Symptoms

Rear liftgate will not stay open on its own
Liftgate slowly drops when released
Liftgate falls quickly when opened — safety hazard
Need to prop liftgate open with a stick or arm
Liftgate harder to lift than when new

How to Fix

Replace both rear liftgate struts at the same time — they are sold in pairs for $30-$80. Installation takes 10-15 minutes with no tools required on most models (the struts pop on and off ball studs). OEM Toyota struts are available for $40-$60 each, and aftermarket options from Stabilus, StrongArm, or Sachs run $15-$30 each. Always replace both struts even if only one has failed — if one is weak, the other is close behind. This is one of the easiest DIY repairs on the Sequoia.

What Owners Are Using

Parts and tips from 0+ owners who fixed this issue

TipThis is a 10-minute DIY repair. The struts pop off the ball studs with a flat-head screwdriver. Buy a pair from Amazon for $30-$50 and replace them yourself. No tools or jack needed.
UpgradeStrongArm liftgate struts — easy bolt-on replacement (StrongArm Liftgate Support Struts)
View on Amazon
UpgradeSachs OE-quality liftgate gas struts (Sachs Liftgate Gas Struts)
View on Amazon

Typical repair cost:$30 - $120

Research This Issue

0+ owners have reported this issue

Google Reddit YouTube NHTSA

Community Reported

High Confidence0 reportsLast reported by owners Invalid DateReviewed Invalid Date

Community Reported

2,400 owners

On the 2001-2009 Toyota Sequoia 2UZ-FE, the 4.7L 2UZ-FE's secondary air injection system fails due to corroded air switching valves (ASVs) and seized air pumps. Moisture enters the system and corrodes internal components. Causes check engine light with P2440/P2442 codes.

This issue also affects: Toyota 4Runner, Toyota Tacoma, Audi A8

Common Symptoms

Check engine light with P2440 or P2442 codes
Rough idle on cold start
Ticking or buzzing noise from air pump on startup
Failed emissions testing

How to Fix

Replace air switching valves (Toyota 25701-50040 and 25702-50011) and air injection pump (Toyota 17610-0S010) if seized. Many owners bypass the system entirely with block-off plates since it only operates during cold start for emissions. Bypass plates available from Trail Gear or fabricated from aluminum.

What Owners Are Using

Parts and tips from 2,400+ owners who fixed this issue

Tip
Tip
UpgradeBluetooth OBD-II scanner for reading engine codes and monitoring live data (BlueDriver Bluetooth OBD2 Diagnostic Scan Tool)
View on Amazon
UpgradeQuality synthetic oil and filter combo for engine maintenance (Mobil 1 Full Synthetic Oil and Filter Bundle)
View on Amazon

Typical repair cost:$100 - $2,000

Research This Issue

2,400+ owners have reported this issue

Google Reddit YouTube NHTSA

Community Reported

High Confidence2,400 reportsLast reported by owners Feb 2026Reviewed Feb 2026

On the 2001-2007 Toyota Sequoia 4.7L 2UZ-FE, the cast iron exhaust manifolds on the 2001-2007 Sequoia 4.7L V8 develop cracks from repeated thermal cycling. The cracks typically appear at the flange where the manifold bolts to the cylinder head or between the runner tubes. A cracked manifold causes an audible exhaust leak (ticking noise on cold start that fades as the manifold expands when hot), a faint exhaust smell near the engine bay, and can eventually trigger a check engine light for catalyst efficiency if exhaust gases bypass the catalytic converter.

This issue also affects: BMW X6, Chevrolet Equinox, Chrysler 200

Common Symptoms

Ticking or tapping noise from engine on cold start
Exhaust noise that fades as engine warms up
Exhaust smell near engine bay or cabin
Check engine light for catalyst efficiency
Visible cracks on exhaust manifold surface
Soot stains around manifold flange area

How to Fix

Replace the cracked exhaust manifold ($300-$600 per side for parts). Both sides should be inspected as cracking often affects both manifolds. The exhaust manifold studs frequently break during removal due to corrosion — budget for stud extraction or replacement ($100-$200 extra). Total repair with gaskets and hardware runs $800-$1,500 per side at a shop. Aftermarket stainless steel headers ($400-$800 per side) are a popular upgrade that resists cracking. Always replace the manifold gaskets during the repair.

What Owners Are Using

Parts and tips from 0+ owners who fixed this issue

NoteSoak the exhaust manifold studs with penetrating oil (PB Blaster) for several days before attempting removal. Broken studs are extremely common on these engines and add significant cost to the repair.
UpgradeWalker catalytic converter — EPA-compliant direct fit (Walker Catalytic Converter)
View on Amazon
UpgradeMagnaFlow catalytic converter — high-flow performance option (MagnaFlow Catalytic Converter)
View on Amazon
UpgradeDorman exhaust manifold — solves cracking issues on many models (Dorman Exhaust Manifold)
View on Amazon
UpgradeDorman exhaust manifold bolt and stud kit (Dorman Exhaust Manifold Hardware Kit)
View on Amazon

Typical repair cost:$800 - $3,000

Research This Issue

0+ owners have reported this issue

Google Reddit YouTube NHTSA

Community Reported

High Confidence0 reportsLast reported by owners Invalid DateReviewed Invalid Date

Frequently Asked Questions

What are the most common Toyota Sequoia problems?

According to Au7o's analysis of 4,000+ owner reports, the 2004-2004 Toyota Sequoia has 4 documented issues. The most frequently reported are: Frame Rust and Structural Corrosion, Secondary Air Injection System Failure (2UZ-FE), Exhaust Manifold Cracking (4.7L 2UZ-FE V8). Of these, 1 is rated critical and should be addressed promptly.

Is the Toyota Sequoia reliable?

The 2004-2004 Toyota Sequoia has 4 known issues documented across 4,000+ owner reports. 1 issue is rated critical: Frame Rust and Structural Corrosion. 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.

How much does it cost to fix common Toyota Sequoia problems?

Repair costs for known Toyota Sequoia issues range from $30 to $5,000, depending on the specific problem and whether you choose DIY or professional repair. The most critical issue, Frame Rust and Structural Corrosion, typically costs $200-$5,000 to repair. Au7o provides step-by-step DIY maintenance guides that can help reduce repair costs.

What is the 2001-2007 Toyota Sequoia Frame Rust and Structural Corrosion?

1st-gen Sequoias in salt-belt states develop severe frame rust, particularly at the rear crossmember, leaf spring mounts, and spare tire carrier area. Toyota issued a Limited Service Campaign (LSC) for some Tundra frames but Sequoias were not included despite sharing the platform… Repairs typically run $200-$5,000. Severity: high.

What is the 2001-2009 Toyota Sequoia Secondary Air Injection System Failure (2UZ-FE)?

The 4.7L 2UZ-FE's secondary air injection system fails due to corroded air switching valves (ASVs) and seized air pumps. Moisture enters the system and corrodes internal components. Causes check engine light with P2440/P2442 codes. Repairs typically run $100-$2,000. Severity: medium.

What is the 2001-2007 Toyota Sequoia Exhaust Manifold Cracking (4.7L 2UZ-FE V8)?

The cast iron exhaust manifolds on the 2001-2007 Sequoia 4.7L V8 develop cracks from repeated thermal cycling. The cracks typically appear at the flange where the manifold bolts to the cylinder head or between the runner tubes. A cracked manifold causes an audible exhaust leak (t… Repairs typically run $800-$3,000. Severity: medium.

What is the 2001-2022 Toyota Sequoia Rear Liftgate Strut Failure (Hatch Won't Stay Open)?

The gas-charged struts that hold the rear liftgate open on the Sequoia lose pressure over time, causing the heavy rear hatch to fall on its own. This is a safety concern as the liftgate is large and heavy enough to injure someone if it drops unexpectedly. The struts typically beg… Repairs typically run $30-$120. Severity: low.

2004 Toyota Sequoia Problems: 4 Issues Every Owner Should Know

All 4 Known Issues

2001-2007 Toyota Sequoia: Frame Rust and Structural Corrosion#

Common Symptoms

How to Fix

What Owners Are Using

Research This Issue

2001-2022 Toyota Sequoia: Rear Liftgate Strut Failure (Hatch Won't Stay Open)#

Common Symptoms

How to Fix

What Owners Are Using

Research This Issue

2001-2009 Toyota Sequoia: Secondary Air Injection System Failure (2UZ-FE)#

Common Symptoms

How to Fix

What Owners Are Using

Research This Issue

2001-2007 Toyota Sequoia: Exhaust Manifold Cracking (4.7L 2UZ-FE V8)#

Common Symptoms

How to Fix

What Owners Are Using

Research This Issue

Other Toyota Models

Frequently Asked Questions

What are the most common Toyota Sequoia problems?

Is the Toyota Sequoia reliable?

How much does it cost to fix common Toyota Sequoia problems?

What is the 2001-2007 Toyota Sequoia Frame Rust and Structural Corrosion?

What is the 2001-2009 Toyota Sequoia Secondary Air Injection System Failure (2UZ-FE)?

What is the 2001-2007 Toyota Sequoia Exhaust Manifold Cracking (4.7L 2UZ-FE V8)?

What is the 2001-2022 Toyota Sequoia Rear Liftgate Strut Failure (Hatch Won't Stay Open)?