2020 Toyota RAV4 Structure

I am writing to formally report a significant structural failure regarding the power liftgate system on my 2020 Toyota RAV4 Hybrid XLE. Recently, the trunk began failing to close properly. Upon a detailed inspection, I discovered that the sheet metal surrounding the hinges has suffered catastrophic failure. The left-side hinge mounting point is severely fractured, and the right side is exhibiting clear stress cracks. This is not a case of "wear and tear." This is a structural failure where the force exerted by the factory power struts appears to have overpowered the vehicle's body structure, leading to metal fatigue and tearing. I would like to emphasize the following points regarding this case: Maintenance & Care: This vehicle has been maintained strictly according to Toyota’s recommended intervals and has been handled with the utmost care. There has been no external impact or misuse of the liftgate. Safety Risk: The inability to securely latch the trunk poses a severe safety hazard. I am concerned about the liftgate's stability at highway speeds and the potential for exhaust fumes to enter the cabin. Consequently, I no longer feel safe using this vehicle for my daily commute. Request for Action: Given that this appears to be a known issue within the 2019–2021 RAV4 production years, I am requesting that Toyota stand behind its reputation for quality and safety. I ask that Toyota cover the full cost of the structural repairs and the replacement of the affected hinges and struts. I trust that Toyota will treat this as a priority safety matter. I look forward to your prompt response regarding a diagnostic appointment and a resolution for these repairs. Sincerely, [XXX] VIN [XXX] Phone Number [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

Rear hatch were repaired new actuators but still malfunctioning now hinges are defective dealer won't honor extended warranty suggest take to body shop have defective hinges replaced at my cost

The hinges for the rear door/hatch broke. The door became unaligned and would not close and I had to drive my vehicle to a repair shop with the rear door ajar. This has not been inspected by manufacturer, no police or insurance inspection either. There is no reason these hinges should be worn and literally torn after 5 years.

The contact owns a 2020 Toyota Rav4. The contact stated that during inclement weather, moisture entered the vehicle through the front passenger side and the rear driver side doors. The contact stated that upon opening both the front passenger’s and the rear driver’s side doors, there was a water swishing sound coming from inside the doors. The vehicle was not diagnosed or repaired. The manufacturer was not notified of the failure. The failure mileage was approximately 58,000.

Lift gate will not close properly. Hinges a top of gate are coming undone. Worried gate will open while driving. Had to manually close and hope it closed.

right rear hinge for hatchback failed and making my hatchback unusable. I have been on several websites and this common issue it seems for Rav 4. Toyota will not fix it.

Power lift gate not opening and shutting then noted that the mount on the passenger side is partially sheared off the car bracket and starting to separate on the drivers side. Was unable to close the hitch all the way, and beeping continuously while driving so brought to a toyota dealer service who ordered replacement pistons, in the mean time battery died due to being unable to close back. Once piston parts were obtained by toyota service center, had to have the car towed due to battery not able to be charged, then they noticed the bolts starting to shear off. Stated they have never seen anything like this but when looked online, found this has been a common problem and a class action suit has been filed for this exact reason

Liftgate hinges on my 2020 RAV4 hybrid XSE failed, causing misalignment so the liftgate/tailgate does not close properly or completely. Liftgate hinges are made of materials that are not strong enough for consistent and safe operation. Toyota has not issued a recall or provided safety warnings or notifications, nor is the company providing replacement hinges. RAV4 owners are left to pay for the replacement of these hinges when it’s a quality issue that can impact the safe operation of 2020 Toyota RAV4s. Toyota recently settled a lawsuit brought by an individual because of this issue.

The contact owns a 2020 Toyota Rav4. The contact stated that while the vehicle was parked, the contact inspected the vehicle and became aware that the hinges on the rear liftgate were bent, and the liftgate was misaligned. The vehicle was not taken to a dealer or independent mechanic to be diagnosed or repaired. The manufacturer was notified of the failure but offered no assistance. The contact was informed that there was no recall on the VIN for the failure. The approximate failure mileage was 22,500.

The door lock actuators required repair on all my doors for the RAV4 2020. They stopped working after the 3 year warranty was up. This is a safety issue. I had to manually lock and unlock my doors, which left in a dangerous position at night. Over the course of a year all 4 doors needed to have the actuators replaced. This happrened in 2024.

What component or system failed or malfunctioned, and is it available for inspection upon request? THE HINGES ARE BROKEN ON THE HATCH How was your safety or the safety of others put at risk? MY SAFETY AS WELL AS OTHERS IS PUT AT RISK BECAUSE THE HINGE IS BROKEN. THE HATCH WILL NOT CLOSE THEREFOR COULD FLY OFF WHILE DRIVING Has the problem been reproduced or confirmed by a dealer or independent service center? THE ISSUE WAS TAKEN TO A DEALERSHIP BUT THEY FOUND NO PROBLEM, ANOTHER APPOINTMENT SCHEDULED TUESDAY10/22 Has the vehicle or component been inspected by the manufacturer, police, insurance representatives or others? NO Were there any warning lamps, messages or other symptoms of the problem prior to the failure, and when did they first appear? NO This is not a rare issue. I have seen dozens upon dozens of articles on Google, Facebook and Reddit of others dealing with the same exact issue. Examples: [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

This vehicle is equipped with a power back door (PBD) that has begun to malfunction. March 29, 2024 was the first occurrence of the PBD malfunction when the opened back door would not fully close after clicking the appropriate button on the electronic key switch. There were no warnings that preceded the malfunction. The PBD would only close the back door a few inches before stopping. Additional clicks only closed it a few more inches and manual closing (requiring significant pressure) was required to fully close the door. Additional random occurrences of this PBD malfunction have happened over the past six months and have now become so frequent that on September 30, 2024 I turned off (via the multi-information display) the PBD function and must now resort to fully manual opening and closing of the back door. Based on multiple other complaints filed with NHTSA for this particular vehicle (2020 Toyota RAV4; NHTSA ID Numbers 11572353, 11572802, 11573768, 11579590, 11585733), I inspected the edges of the back door, the body's back door cavity, and the two back door spindles for damage, foreign objects, dirt, etc. that might impede PDB operation and found none. I also inspected the two back door hinges and saw no damage, no warping, no corrosion, and no movement of the hinges from their original installation locations. This PBD malfunction affects safety as the force required to manually open and close the back door is significant and operation of the back door might be impossible for people not physically able to effect the force needed. The vehicle is available for inspection and has not yet been inspected by the Toyota dealer where I purchased the vehicle in August 2020 or by others.

The contact owns a 2020 Toyota Rav4. The contact stated that while the vehicle was parked, the passenger’s side rear side door became flooded after inclement weather. The contact stated that while attempting to open the door, there was a slushing sound coming from the door. The vehicle was not taken to be inspected. The vehicle was not repaired, and the failure persisted. The manufacturer was notified of the failure. The failure mileage was 68,000.

The contact owns a 2020 Toyota Rav4. The contact stated that while operating the vehicle, there was an abnormal sound of slushing water coming from inside the front driver’s side door panels. Additionally, water from the door panels had leaked into the cabin of the vehicle. The vehicle was taken to the local dealer who informed the contact that the door seals were faulty and needed to be replaced, and the drainage holes needed to be modified. The vehicle was not yet repaired. The contact was concerned that mold contamination might occur due to the failure. The manufacturer was notified of the failure. The failure mileage was 6,000.

Tailgate hinge assembly failed/failing. It is available for inspection upon request. Failed hinge has placed the tailgate out of alignment. This prevents the tailgate to close properly, allowing for weather penetration, as well as preventing full closure of tailgate. This safety concern can potentially allow the tailgate to fall off the vehicle during travel, placing myself and others at risk of severe injury. The problem has not been confirmed/reproduced by a dealer or independent service center. The vehicle/component has not been inspected by any other representatives. There were no warning lamps, or any other symptoms prior to failure. This problem first occurred at 0625am, FEB09_2024. Tailgate opened with no issues. Tailgate failed to close on its own, due to misalignment.

The hinges on the lift gate are detaching causing my trunk not to close all the way.

The contact owns a 2020 Toyota Rav4. The contact stated that the driver's side and passenger's side rear doors were retaining water. The water was sloshy inside the doors while driving. The contact had to drain the water from both doors. There were no warning lights illuminated. The local dealer was contacted, but the vehicle was not diagnosed or repaired. The manufacturer was not made aware of the failure. The failure mileage was approximately 2,500.

The contact's son owns a 2020 Toyota RAV4. The contact stated that when it rained, rainwater entered the vehicle onto the passenger’s side front door panel. The contact stated that the sound of the water slushing around in the front passenger's door panel was very distracting. The vehicle was taken to the dealer where it was diagnosed with a failed door trim. The contact was informed that the front passenger’s side door trim needed to be cut and drained. The contact stated that there was more than a gallon of water released from the front passenger's side door panel drain. The vehicle was repaired. The manufacturer was not made aware of the failure. The failure mileage was approximately 111,000. The VIN was not available.

When driving down the road at a relatively high speed, the sunroof unexpectedly shattered, which could have led to an accident.

For about a year now the back hatch has not opened or closed properly. It sometimes stops just after the latch releases and will not go up. Sometimes it will not come down when you use the switch or it only comes down a few inches and stops. Recently the rear hatch is not aligned with the door opening and does not shut properly. When the rear hatch is closed, you can see that it is not seated in the opening. One side is still open. You can hear road noise from the rear hatch. I worry that exhaust fumes are getting in the rear hatch.

OVER A PERIOD OF TME WATER HAS BEEN COLLECTING IN THE RIGHT REAR DOOR. UPON DOING SOME RESEARCH I FOUND OUT THAT THIS IS A PROBLEM WITH THE RAV4 OF THIS PARTICLE YEAR. DURING MY SEARCH I FOUND OUT THAT THERE ARE DRAIN HOLES AT BOTTOM OF THE DOOR UNDER A RUBBER GASKET. I LIFTED THE GASKET UP AND THERE WAS A LARGE AMOUNT OF WATER THAT CAME OUT. AFTER A COUPLE MORE RAINS THE EXACT SAME THING HAPPENED AGAIN. I TOOK THE CAR TO THE TOYOTA DEALERSHIP WHERE IT WAS PURCHASED FROM AND TOLD THEM THE PROBLEM AND THEY STATED THAT THE GASKET ON THE BOTTOM OF THE DOOR NEEDED TO BE REPLACED , BUT NOT ONLY THE RIGHT REAR DOOR BUT ALL THREE OF THE OTHER DOORS AS WELL, BUT COULD NOT EXPLAIN TO ME HOW THE WATER WAS GETTING IN THE DOORS. I HAD TO PAY OVER $500 IN ORDER TO GET THIS REPAIR WHICH I FEEL THE COST SHOULD BE ABSORBED BY TOYOTA BECAUSE A DESIGN FLAW. ANY HELP WOULD BE APPRECIATED.

The contact owns a 2020 Toyota Rav4. The contact stated while the vehicle was parked, the front driver's and both passenger's side doors were filled with water inside the door panels. The contact stated that the water had to be shaken out of the door panels. The vehicle was not diagnosed or repaired by an independent mechanic. The contact stated that while the vehicle was at the dealer being serviced, the dealer unofficially informed the contact that the failure was due to failed door seals. The manufacturer was not made aware of the failure. The failure mileage was approximately 25,000.

Sunroof shattered while driving.

Under normal use, the rear Lift gate hinge appears to be failing for no reason. A gap on passenger side of the rear lift gate and body appears to widen and the hinge is squeaking as if it's failing. This causes the power lift gate to not close from time to time. This is still an issue and has not been addressed yet.

Torn bracket holding very rear door in place