2012 Toyota FJ Cruiser Problems: 14 Known Issues

On the 2007-2012 Toyota FJ Cruiser 4.0L V6 (1GR-FE), the plastic driver footrest / dead pedal breaks away from its mounting clips and becomes a loose object in the driver footwell. In documented complaints the detached footrest slid under the pedals; in at least one NHTSA-reported case it lodged under the brake pedal and prevented the driver from depressing the brake, making it a genuine safety hazard rather than a mere annoyance.

On the 2007-2013 Toyota FJ Cruiser, on the FJ Cruiser the front seat belt retractors are mounted inside the rear-hinged access (suicide) doors, not the B-pillar. Toyota found the access door inner panel had insufficient strength: when the access doors are repeatedly and forcefully slammed over time, cracks develop in the panel around the lower retractor anchor. If the panel cracks through, the retractor can detach and the front belt will not restrain the occupant in a crash. About 209,000 FJ Cruisers (2007 through late-2013 model years) were covered.

On the 2007-2014 Toyota FJ Cruiser, fJ Cruisers develop significant frame rust in salt-belt states, especially at the rear crossmember and trailing arm mounts. The frame design has areas where water and debris collect, accelerating corrosion. Rising FJ Cruiser values make frame preservation critical.

On the 2007-2014 Toyota FJ Cruiser, the FJ Cruiser's nearly flat windshield design makes it highly susceptible to cracking from small impacts that would be deflected by more curved windshields. Owners report going through multiple windshields over the life of the vehicle. The flat angle also causes more direct stone impacts.

On the 2007-2014 Toyota FJ Cruiser 4.0L V6 (1GR-FE), the thin sheet-steel inner fender aprons in the engine bay develop bulges that eventually crack and tear, typically a 3-4 inch tear in the upper inner fender roughly 6-8 inches from the firewall on both sides. It is attributed to metal fatigue from frame/body flex combined with aprons too thin to let the body mounts work properly. It affects even garage-kept and never-off-road examples; early (2007-2008) trucks are worst and Toyota later added reinforcement.

On the 2007-2014 Toyota FJ Cruiser 4.0L V6 (1GR-FE), the side-hinged rear cargo door carries the full-size spare (and often aftermarket tire carriers, gas cans, or heavier wheels). Over time the pinch-seam spot welds on the door crack and the door sags roughly half an inch, so it no longer aligns and must be lifted to latch. Rust developing from within the tailgate compounds the problem. It is aggravated by heavy tires/wheels and violent door swings during off-road use.

On the 2007-2012 Toyota FJ Cruiser, tRD brake kits (P/N PTR09-35070) and TRD High-Performance brake kits (P/N PTR09-35100), installed at Toyota processing centers or sold by dealers as accessories on 2007-2012 FJ Cruisers, route the outer caliper brake tube with minimal clearance to the TRD 16-inch 6-spoke alloy wheel. If balance weights are stuck in the wrong spot, they rub the tube until it is damaged and leaks brake fluid, increasing stopping distance and potentially losing front braking.

On the 2007-2014 Toyota FJ Cruiser, the rear differential breather on the FJ Cruiser is located low on the axle housing and is prone to clogging with mud and debris. When clogged, pressure builds during heating cycles and forces gear oil past the pinion seal. During water crossings, the breather can suck water into the differential as the hot housing cools rapidly, contaminating the gear oil.

On the 2007-2014 Toyota FJ Cruiser, fJ Cruiser owners report rear axle shaft oil seals leaking gear oil into the brake backing plate area, coating the inside of the dust shield, the rotor/drum-in-hat parking brake shoes and sometimes pads. A clogged differential breather pressurizes the housing and accelerates seal leaks (the breather clog itself is a separate catalog issue).

On the 2007-2014 Toyota FJ Cruiser, the FJ Cruiser's A/C system is prone to compressor clutch failure and evaporator core leaks. The evaporator is located behind the dashboard, making replacement extremely labor-intensive. The A/C system struggles in hot climates, especially when off-roading at low speeds.

On the 2010-2014 Toyota FJ Cruiser 4.0L V6 (1GR-FE), the 1GR-FE's secondary air injection system, used to reduce cold-start emissions, is prone to failure. Water/condensation intrusion corrodes the air pump and air switching valves, or a broken plastic impeller sheds debris into the system, triggering the check engine light and often limp mode. It is most common in cold and wet climates and can strand the vehicle in reduced-power mode.

On the 2007-2014 Toyota FJ Cruiser 4.0L V6 (1GR-FE), the A750F 5-speed automatic behind the 4.0L V6 develops a distinct shudder/judder felt as a vibration typically between roughly 35-50 mph under light throttle when the torque converter clutch engages during 'Flex Lockup.' It is caused by aged/degraded Toyota WS fluid losing its friction modifier, producing a stick-slip grab of the lockup clutch; in higher-mileage cases the converter clutch itself has failed. It is frequently confused with an engine misfire because it feels identical.

On the 2007-2014 Toyota FJ Cruiser 4.0L V6 (1GR-FE), a common age/mileage failure on the 1GR-FE Denso starter: the high-current contacts inside the starter solenoid erode or corrode, so turning the key produces a single click with no crank, often intermittently and worse when hot or after moisture/salt exposure. Repeated key cycling sometimes clears enough contamination to crank, a classic tell of worn solenoid contacts rather than a dead battery.

On the 2007-2013 Toyota FJ Cruiser, recall 13V163 / D0G concerns 2007–2013 FJ Cruisers fitted with the Genuine Toyota Auxiliary Light Kit on the front bumper. Its original 55-watt lamps, used with the high beams, exceed an allowable lighting threshold and can cause glare. Toyota identified approximately 11,500 accessory kits; about 209,000 owner letters were planned to reach dealer-installed and over-the-counter installations as well. A vehicle without the kit is not involved.