2015 Toyota Sienna Body & Structure Problems

See attached document for complaint.

The contact owns a 2015 Toyota Sienna. While the vehicle was parked, the contact discovered that the fuel lid door hinge had fractured, causing the fuel lid to intermittently fail to open or close as needed. The contact stated that with the fuel lid intermittently inoperative, the rear driver’s side door failed to open when needed. No warning lights were illuminated. The vehicle was taken to an independent mechanic where it was determined that the fuel lid door and hinge needed to be replaced. The vehicle was not repaired. The manufacturer was notified of the failure. The failure mileage was approximately 117,000.

Fuel filler door upper hinge failed so that door would not seat properly when closed. Because the door was not seated properly, the left side power sliding door interlock did not release, preventing the sliding door from opening fully. I had visited a fast food restaurant in Feb 2025 and ordered some French fries for my[XXX], strapped into his child seat directly behind the driver. He was choking on a fry, starting to turn blue. I quickly stopped and attempted to open the sliding power door, but it would not open fully to allow access to my grandson because the failing fuel door wouldn't release the power door interlock. By the time I ran around to the passenger side to reach him he had nearly passed out, but I reached him in time to extract him from the seat and performed a Heimlich to expel the fry and restore his breathing. Toyota should be forced to extend the extended warranty for the full duration of the court agreement of 10yr, Dec 2025, regardless of purchase date. My request for fuel door replacement in Jul 2025 was refused because Toyota claimed the warranty was only good until 10yr after date of purchase, not to the end of 2025. The warranty period applies to vehicles purchased Dec 2025, so the warranty program still exists, but Toyota National refuses to honor it for my vehicle. The inoperable power door can cause passengers to be trapped from quick exit in case of other emergencies, such as vehicle fire or accident rollover. Toyota should honor the warranty or risk legal liability for a death due to manufacturer defect! INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

Cable that controls sliding door broke. Door now pops open about 1cm, not enough that you notice that it is open and when you drive it slides open more. It also can't be closed with the button and it's not easy to close.

sunroof exploded while driving

SLIDING DOOR CABLE SNAPPED WHILE OPENING. NOT DUE TO WEATHER.

THE CABLE TO MY SIDE POWER PANEL DOOR SNAPPED YESTERDAY. IT IS HANGING FROM THE SIDE OF MY CAR - WHAT DOESN'T SEEN RIGHT IS THAT THE CABLE IS RUSTY - IT LOOKS LIKE IT SNAPPED BECAUSE IT IS WAS EXPOSED TO MOISTURE. THE DOOR IS COMPLETELY UNUSABLE - I CANNOT OPEN IT USING THE MANUAL OR POWER MODE. MY VAN IS IN MY TEMPERATURE CONTROLLED GARAGE THE MAJORITY OF THE TIME AND THERE SHOULD BE NO REASON THAT THE CABLE IS SHOWING SIGNS OF RUST OTHER THAN A DESIGN FLAW.

2015 SIENNA [XXX] DOORS WOULD NOT CLOSE AFTER OPENING WITH THE KEYFOB. COULD NOT CLOSE DOORS WITH THE ENGINE RUNNING AND USING INTERNAL BUTTONS ON ALL LOCATIONS HAD TO MANUALLY CLOSE DOORS. THE VEHICLE WAS PARKED. THIS HAPPENED TWICE RECENTLY, 6/12/2020 AND 7/1/2020 INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6). *CC *TR

WELD ON FUEL DOOR IS BROKEN, IS THIS A DEFECT IN THE MANUFACTURING.FUEL DOOR WILL NOT CLOSE PROPERLY. I PURCHASED USED AND I NOTICED IT WAS BROKEN FIRST TIME I PURCHASED GAS.

WE HAVE A PROBLEM WITH OUR DRIVER SIDE SLIDING DOOR. IT STARTED OF NOT OPENING UP WHEN HANDLE WAS PULLED, NOW IT OPENS BUT DOESN'T CLOSE AUTOMATICALLY.

RECALL ISSUED FOR POWER SIDE DOORS OPENING ON THEIR OWN WHILE DRIVING. WAS CORRECTED, BUT IS HAPPENING AGAIN. DEALER INFORMED US THAT WE WOULD HAVE TO PAY TO GET THE OPENING CORRECTED. IS TOYOTA OR THE CONSUMER RESPONSIBLE FOR PAYMENT FOR THE SECOND, THIRD OR FOURTH REPAIR?

THE DRIVER AND PASSENGER BACK SLIDING DOORS BOTH OF THEM GET JAMMED AT TIMES AND IT WON'T OPEN AND THERE A RE CALL FOR IT AND THEY WERE SUPPOSED TO CALL ME BACK WHEN THEY GOT THE PART AND AS OF TODAY (3-31-19) I HAVEN'T RECEIVED A CALL. PLEASE CAN WE SOLVE THIS PROBLEM? I'VE HAD THE CAR FOR A YEAR AND HALF AS OF THE DATE THAT I WROTE AND NO ONE HAS EVER CALLED NOR SEND ME A LETTER. THANK YOU.

IN JANUARY 2019, AT APPROXIMATELY 71,000 MILES, THE UPPER HINGE OF THE FUEL FILLER DOOR (THE DOOR COVERING THE GAS TANK ACCESS) FAILED. THIS APPEARS TO HAVE BEEN CAUSED BY PRESSURE EXERTED ON THE DOOR BY THE SAFETY SWITCH GOVERNING THE DRIVER SIDE SLIDING PASSENGER DOOR. APPARENTLY, THIS IS A WELL-DOCUMENTED ISSUE NOT JUST ON NHTSA (CASE ID# #11104672, 11025478), BUT ALSO WITH TOYOTA (TICKET # 1807172274), AND DOCUMENTED IN PUBLIC FORUMS SUCH AS HTTP://WWW.SIENNACHAT.COM/FORUM/67-PROBLEMS-MAINTENANCE-REPAIR-GEN-3/19274-FUEL-FILLER-DOOR-HINGE-BROKE-ANYONE-ELSE-HAVE-HAPPEN.HTML#. I HAVE TAKEN MY CAR BOTH TO A LOCAL REPAIR SHOP AND TO TOYOTA AND HAVE BEEN TOLD THAT IT IS NOT A WARRANTY ISSUE AND WOULD COST OVER $400 TO FIX. I BELIEVE THAT THIS IS A MECHANICAL DESIGN DEFECT THAT COULD NOT HAVE BEEN FORESEEN DUE TO THE PRESSURE PREVIOUSLY MENTIONED. IN ADDITION, I STRONGLY BELIEVE THAT IT COULD CAUSE A SAFETY ISSUE IN THE CASE OF AN ACCIDENT, AS IT WILL PREVENT THE OPENING OF THE REAR PASSENGER DOOR WHEN THE SWITCH IS ACTIVATED.

THE TRUNK DOOR HAS FAILED. IT DOES NOT STAY UP WHEN YOU OPEN IT WITH EITHER THE REMOTE OR FROM INSIDE THE CAR. THE DOOR WILL OPEN BUT WILL NOT STAY UP... IT FALLS RIGHT BACK DOWN. THE INDICATOR THAT THE DOOR IS OPEN CONTINUES TO BUZZ AS YOU DRIVE BECAUSE WHEN THE DOOR FALLS BACK DOWN-- IT DOES NOT COMPLETELY CLOSE

THE SIDE POWER SLIDING DOORS WILL NOT CLOSE COMPLETELY 100% OF THE TIME USING THE AUTOMATED SYSTEM WHEN IN PARK. THIS IS HAPPENING IN BOTH DOORS. RECALL ON THE DOORS OPENING WHILE OPERATING VEHICLE HAS BEEN PERFORMED. THIS HAPPENS MORE ON AN INCLINE BUT DOES HAPPEN ON FLAT GROUND. SEEMS MORE PREVALENT WHEN THE DOORS ARE USED FREQUENTLY.

THE SLIDING DOORS ON BOTH SIDES ARE NOT CLOSING WITH THE CLOSER BUTTONS. IT GOES SO FAR AND THEN OPENS BACK UP. YOU HAVE TO HOLD ONTO THE DOOR AND FORCE IT TO CONTINUE TO CLOSE. EVEN WHEN STATIONARY WITH THE VAN IN PARK THE DOORS HAVE COME OPEN WITHOUT ANYONE NEAR THEM. I AM WORRIED THEY WILL OPEN WHILE I AM DRIVING. THIS HAS HAPPENED MULTIPLE TIMES THE MOST RECENT WAS TODAY.

TL* THE CONTACT OWNS A 2015 TOYOTA SIENNA. THE CONTACT RECEIVED NOTIFICATION OF NHTSA CAMPAIGN NUMBER: 16V858000 (STRUCTURE); HOWEVER, THE PART FOR THE RECALL REPAIR WAS UNAVAILABLE. THE CONTACT STATED THAT THE MANUFACTURER EXCEEDED A REASONABLE AMOUNT OF TIME FOR THE REPAIR. THE CONTACT CALLED THE FOLSON LAKE TOYOTA DEALER WHO INFORMED THE CONTACT THAT THE PARTS WERE NOT AVAILABLE. THE MANUFACTURER WAS NOT MADE AWARE OF THE ISSUE. THE CONTACT HAD NOT EXPERIENCED A FAILURE. VIN TOOL CONFIRMS PARTS NOT AVAILABLE.

POWER DOOR MALFUNCTION. THE RIGHT BACK PASSENGER DOOR AT TIMES WOULD RANDOMLY CLOSE ON ITS OWN AND OTHER TIMES THE DOOR BEEPS, BUT DOES NOT CLOSE. IT HAS HAPPENED AT LEAST 5 TIMES IN THE PAST 6 MONTHS. IT HAPPENED AGAIN TODAY, 7/3/17.

TL* THE CONTACT OWNS A 2015 TOYOTA SIENNA. THE CONTACT RECEIVED NOTIFICATION OF NHTSA CAMPAIGN NUMBER: 16V858000 (STRUCTURE) HOWEVER,THE PART FOR THE RECALL REPAIR WAS UNAVAILABLE. THE CONTACT STATED THE MANUFACTURER EXCEEDED A REASONABLE AMOUNT OF TIME FOR THE RECALL REPAIR. THE CONTACT STATED THE VEHICLE'S DOOR WOULD SUDDENLY OPEN. THE CONTACT CALLED THE JOSEPH TOYOTA DEALER AND THE CONTACT WAS INFORMED THAT PARTS WERE NOT AVAILABLE. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE AND OPENED CASE NUMBER: 1703012260. THE APPROXIMATE FAILURE MILEAGE WAS 30,000. VIN TOOL CONFIRMS REMEDY NOT YET AVAILABLE. UPDATED 08/23/17*LJ THE CONSUMER STATED THE VEHICLE WAS REPAIRED.*JS

TOYOTA STATED IN THEIR RECALL THAT THERE WOULD BE RESOLUTION BEFORE JANUARY, IT IS NOW JUNE AND STILL NO RESOLUTION ON PASSENGER DOOR RECALL