2015 Toyota Sienna body problems

STRUCTURE:BODY

In August 2025, AutoNation Toyota on Sahara, checked the VIN of my Toyota Sienna and contacted Toyota while I was present. Toyota confirmed a broken fuel-door hinge was covered under a Customer Support Program. Instead, AutoNation attempted to repair, rather than replace, the hinge. This caused the metal fuel cap door to end up bent, paint to be gouged out from the bottom of the fuel door area, misalignment of the fuel door, and therefore issues with the door’s sensor reading correctly. I took the van back until they received shipment of a new fuel cap door. After the attempted repair, since the fuel door no longer aligned, the safety sensors repeatedly activated which strained the sliding-door ECU. The passenger sliding door began freezing intermittently, forcing my children to exit through the trunk several times. Finally, the door opened on its own as I was driving down the street. These issues did not exist prior to dealership service and presented a clear safety concern. Between October and December, I received conflicting explanations from Gerald, James, Ivan, and Rudy at AutoNation Toyota regarding whether the issue involved the fuel door, ECU, motor, or general wear and tear. AutoNation repeatedly failed to return my calls or respond to the emails I sent them. Toyota Corporate also informed me the dealership was also not responding to their outreach attempts after I contacted them due to not being able to get ahold of AutoNation Toyota. I emailed four managers on October 15 with detailed documentation and received no response. My vehicle remains unsafe, unrepaired, and in the possession of AutoNation Toyota. I approve allowing it to be inspected. While at AutoNation, the vehicle driver could not open the passenger sliding door after AutoNation's attempted repair. They have had my van for 4 months now so no one else has looked at or inspected it. There were no warning lamps, messages or other symptoms of the problem prior to the failure.

NHTSA complaint #11713421 — an unverified report by a vehicle owner.

STRUCTURE:BODY:DOOR

See attached document for complaint.

NHTSA complaint #11692382 — an unverified report by a vehicle owner.

STRUCTURE

See attached document for complaint.

NHTSA complaint #11692382 — an unverified report by a vehicle owner.

STRUCTURE:BODY:DOOR:HINGE AND ATTACHMENTS

See attached document for complaint.

NHTSA complaint #11692382 — an unverified report by a vehicle owner.

STRUCTURE:BODY

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)

NHTSA complaint #11676320 — an unverified report by a vehicle owner.

STRUCTURE

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.

NHTSA complaint #11663672 — an unverified report by a vehicle owner.

STRUCTURE:BODY

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.

NHTSA complaint #11550327 — an unverified report by a vehicle owner.

STRUCTURE:BODY

sunroof exploded while driving

NHTSA complaint #11436200 — an unverified report by a vehicle owner.

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

NHTSA complaint #11353820 — an unverified report by a vehicle owner.

STRUCTURE:BODY

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.

NHTSA complaint #11348896 — an unverified report by a vehicle owner.

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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

NHTSA complaint #11337372 — an unverified report by a vehicle owner.

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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.

NHTSA complaint #11246523 — an unverified report by a vehicle owner.

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3 ISSUE WITH 5TDKK3DC2FS[XXX] TOYOTA SIENNA 2015 LE VAN *1 - SEAT BELT - 2ND ROW DRIVER SIDE SEAT BELT CANNOT BE WEAR. CANNOT WEAR SEAT BELT AS THE RED PART THAT FASTENS THE SEAT BELT CLIP DOES NOT WORK. UNABLE TO FASTEN SEAT BELT IN THE 2ND ROW SEAT BEHIND DRIVER. 2* AT 30,000 MILES WITH PROPER CAREFUL DRIVING BRAKE LIGHTS TURN ON IN RAIN - ALL THE LIGHTS START TO FLASH IN DASHBOARD. *3- FRONT DRIVER SIDE BUMBER WHERE IT MEETS THE FENDER DOES NOT HOLD BUMPER PROPERLY. THE CLIPS THAT HOLD BUMPER ARE NOT MADE PROPERLY. I HAVE SEEN AT LEAST 4 TOYOTA SIENNA WITH SAME ISSUES AT DIFFERENT PLACES OF SAME MODEL / DESIGN. WHEN PUSH BACK TO FIX THE NUMBER IT STAYS AND AFTER SHORT 5-10 MILES DRIVE IT COMES BACK LOOSE AGAIN. SO I HAVE TO KEEP PUSHING THE BUMPER BACK. I HAVE THE VAN FOR OVER A YEAR NOW. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6).

NHTSA complaint #11243729 — an unverified report by a vehicle owner.

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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.

NHTSA complaint #11243071 — an unverified report by a vehicle owner.

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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?

NHTSA complaint #11218558 — an unverified report by a vehicle owner.

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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.

NHTSA complaint #11207681 — an unverified report by a vehicle owner.

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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.

NHTSA complaint #11192813 — an unverified report by a vehicle owner.

STRUCTURE:BODY:HATCHBACK/LIFTGATE:SUPPORT DEVICE/STRUT

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

NHTSA complaint #11172122 — an unverified report by a vehicle owner.

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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.

NHTSA complaint #11153109 — an unverified report by a vehicle owner.

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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.

NHTSA complaint #11123569 — an unverified report by a vehicle owner.

STRUCTURE:BODY

MY SLIDING DOORS OPEN WHENEVER AND SOMETIMES DO NOT CLOSE ALL THE WAY. WHEN THE SLIDING DOOR IS BETWEEN 6 AND 8 INCHES TO CLOSE IT WILL STOP AND OPEN ALL THE WAY. I HAVE BEEN TO BYERS TOYOTA 4 MAYBE 5 SEPARATE TIMES WITH THIS PROBLEM. BYERS SAYS THAT THE DOORS HAVE BEEN FIXED NUMEROUS TIMES. IT STILL DOES WHAT BYERS SAID THEY HAVE FIXED IT. PHONE NUMBER FOR BYERS 614-923-1101 ASKED FOR TARA IN SERVICE. MY NUMBER IS [XXXX]. THIS HAS HAPPENED EVEN WHEN IN MOTION. PARTS OF THIS DOCUMENT HAVE BEEN REDACTED TO PROTECT PERSONALLY IDENTIFIABLE INFORMATION PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6).

NHTSA complaint #11110189 — an unverified report by a vehicle owner.

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TAKATA RECALL: SUMMARY IN THE INVOLVED VEHICLES, THERE IS A POSSIBILITY THAT UNDER CERTAIN LIMITED CONDITIONS, IF THE SLIDING DOOR OPENING OPERATION IS IMPEDED, THE SLIDING DOOR MOTOR CIRCUIT COULD BE OVERLOADED, OPENING THE FUSE FOR THE MOTOR. SAFETY RISK IF THIS OCCURS WHEN THE DOOR LATCH IS IN AN UNLATCHED POSITION, THE DOOR COULD OPEN WHILE DRIVING, INCREASING THE RISK OF INJURY TO A VEHICLE OCCUPANT. THIS VEHICLE IS INVOLVED IN PHASE 1 OF THIS SAFETY RECALL. PHASE 1 COVERS THE VAST MAJORITY OF VEHICLES INVOLVED IN THIS RECALL AND THE REMEDY IS CURRENTLY AVAILABLE FOR THESE VEHICLES. FOR THE VEHICLES INVOLVED IN PHASE 1, ANY AUTHORIZED TOYOTA DEALER WILL REPLACE THE INSTRUMENT PANEL JUNCTION BLOCK AND INSTALL NEW WIRE HARNESSES CONNECTING IT TO THE POWER SLIDING DOORS. BUT THE PRE-OWNER MISS THIS RECALL, AND I BUY THIS VEHICLE FROM CARMAX, THEY LET ME FINISH THIS RECALL.

NHTSA complaint #11074894 — an unverified report by a vehicle owner.

STRUCTURE:BODY:DOOR

2015 TOYOTA SIENNA. CONSUMER WRITES IN REGARDS TO VEHICLE DOOR OPENS/MALFUNCTION WHILE DRIVING. *LD UPDATED 11/8/2017

NHTSA complaint #11021973 — an unverified report by a vehicle owner.

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PASSENGER SIDE POWER SLIDING DOOR CONSTANTLY MALFUNCTIONING. IT OPENED AFTER A BUMP WHILE TRAVELING 65 MPH ON THE INTERSTATE. WE HAD TO PULL OVER TO CLOSE THE DOOR. IT ALSO DEPLOYED THE WHEELCHAIR RAMP WHILE MOVING BECAUSE THE POWER DOOR IS THE SAME SIDE AS THE RAMP.. MAKE THE MANUFACTURER FIX IT OR MAKE THE WHEELCHAIR CONVERSION COMPANY FIX IT. SOMEBODY NEEDS TO FIX THIS BEFORE SOMEBODY DIES! ALL THIS RED TAPE AND ZERO ACTION IS INSANE. PEOPLE ARE GETTING INJURED WHILE THE FINGER POINTING IS HAPPENING. WHEN WILL SOMETHING BE DONE? HOW MANY INJURIES HAVE TO OCCUR BEFORE AN ACTION STEP OCCURS?

NHTSA complaint #11032817 — an unverified report by a vehicle owner.

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TL* THE CONTACT OWNS A 2015 TOYOTA SIENNA. THE CONTACT RECEIVED NOTIFICATION OF NHTSA CAMPAIGN NUMBER: 16V858000 (STRUCTURE); HOWEVER, THE PART TO DO THE REPAIR WAS UNAVAILABLE. THE CONTACT STATED THAT THE MANUFACTURER EXCEEDED A REASONABLE AMOUNT OF TIME FOR THE RECALL REPAIR. FOOTHILLS TOYOTA IN BURLINGTON, WASHINGTON WAS MADE AWARE OF THE RECALL AND STATED THAT THE PARTS WERE UNAVAILABLE. THE MANUFACTURER WAS MADE AWARE OF THE ISSUE. THE CONTACT HAD NOT EXPERIENCED A FAILURE. VIN TOOL CONFIRMS PARTS NOT AVAILABLE.

NHTSA complaint #11025374 — an unverified report by a vehicle owner.

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TL* THE CONTACT OWNS A 2015 TOYOTA SIENNA. THE CONTACT STATED THAT THE DRIVER SIDE SLIDING DOOR FAILED TO OPERATE MANUALLY AND WHEN USING THE OVERHEAD DOOR SWITCH. THE CONTACT CALLED MCCORDS TOYOTA IN VANCOUVER, WA WHERE IT WAS CONFIRMED THAT THE PART FOR THE RECALL REPAIR WAS NOT AVAILABLE. THE DEALER WAS NOT SURE WHEN THE PART WOULD BECOME AVAILABLE. THE CONTACT RECEIVED NOTIFICATION OF NHTSA CAMPAIGN NUMBER: 16V858000 (STRUCTURE); HOWEVER, THE PART NEEDED FOR THE REPAIR WAS NOT AVAILABLE. THE CONTACT STATED THAT THE MANUFACTURER EXCEEDED A REASONABLE AMOUNT OF TIME FOR THE RECALL REPAIR. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 16,000. UPDATED 11/13/17 *BF UPDATED 11/16/2017

NHTSA complaint #11012193 — an unverified report by a vehicle owner.

STRUCTURE:BODY:DOOR

TL* THE CONTACT OWNS A 2015 TOYOTA SIENNA. THE CONTACT STATED THAT THE DRIVER SIDE SLIDING DOOR FAILED TO OPERATE MANUALLY AND WHEN USING THE OVERHEAD DOOR SWITCH. THE CONTACT CALLED MCCORDS TOYOTA IN VANCOUVER, WA WHERE IT WAS CONFIRMED THAT THE PART FOR THE RECALL REPAIR WAS NOT AVAILABLE. THE DEALER WAS NOT SURE WHEN THE PART WOULD BECOME AVAILABLE. THE CONTACT RECEIVED NOTIFICATION OF NHTSA CAMPAIGN NUMBER: 16V858000 (STRUCTURE); HOWEVER, THE PART NEEDED FOR THE REPAIR WAS NOT AVAILABLE. THE CONTACT STATED THAT THE MANUFACTURER EXCEEDED A REASONABLE AMOUNT OF TIME FOR THE RECALL REPAIR. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 16,000. UPDATED 11/13/17 *BF UPDATED 11/16/2017

NHTSA complaint #11012193 — an unverified report by a vehicle owner.

STRUCTURE:BODY

2015 TOYOTA SIENNA MINI VAN BOUGHT NEW. STILL COVERED BY 36 MONTH WARRANTY WITH 30,000 MILES. POWER SLIDING DOORS UNDER RECALL. OBSERVED SIGNIFICANT RUST ON METAL PLATE BOLTED ON DOOR HINGE COVERING ELECTRICAL WIRES. IF METAL COVER RUSTS THRU, COULD LEAD TO SHORT AND ELECTRICAL DOOR MOTOR FAILURE. TOYOTA REFUSES TO REPLACE METAL COVER PLATE. I FEEL TOYOTA SHOULD HONOR WARRANTY AND REPLACED RUSTED PARTS.

NHTSA complaint #11010986 — an unverified report by a vehicle owner.

STRUCTURE:BODY

TL* THE CONTACT OWNS A 2015 TOYOTA SIENNA. THE CONTACT RECEIVED NOTIFICATION OF NHTSA CAMPAIGN NUMBER: 16V858000 (STRUCTURE); HOWEVER, THE PART TO DO THE REPAIR WAS UNAVAILABLE. THE CONTACT STATED THAT THE MANUFACTURER EXCEEDED A REASONABLE AMOUNT OF TIME FOR THE RECALL REPAIR. ONE TOYOTA IN OAKLAND, CALIFORNIA WAS CONTACTED ABOUT THE RECALL AND STATED THAT THE PARTS WERE UNAVAILABLE. THE MANUFACTURER WAS NOT MADE AWARE OF THE ISSUE. THE CONTACT HAD NOT EXPERIENCED A FAILURE. PARTS DISTRIBUTION DISCONNECT.

NHTSA complaint #11005386 — an unverified report by a vehicle owner.

STRUCTURE:BODY:DOOR

TL* THE CONTACT OWNS A 2015 TOYOTA SIENNA. THE CONTACT STATED THAT THE SLIDING DOORS WERE CONSTANTLY OPENING INDEPENDENTLY. THE FAILURE WAS PERSISTENT. THE VEHICLE WAS TAKEN TO A LOCAL DEALER (MIKE WOOD TOYOTA OF UNIONTOWN 1 MARY JANE WOOD DRIVE, UNIONTOWN, PA 15401) WHERE IT WAS DIAGNOSED THAT THE DOOR MOTOR FAILED AND NEEDED TO BE REPLACED. THE VEHICLE WAS REPAIRED, BUT THE FAILURE RECURRED. THE VEHICLE WAS TAKEN BACK TO THE LOCAL DEALER WHO CONFIRMED THAT THE VIN WAS INCLUDED IN A RECALL. THE CONTACT RECEIVED NOTIFICATION OF NHTSA CAMPAIGN NUMBER: 16V858000 (STRUCTURE). THE PART TO DO THE RECALL REPAIR WAS UNAVAILABLE. THE CONTACT STATED THAT THE MANUFACTURER EXCEEDED A REASONABLE AMOUNT OF TIME FOR THE RECALL REPAIR. THE MANUFACTURER WAS MADE AWARE OF THE ISSUE AND WAS NOT ABLE TO CONFIRM WHEN THE PARTS WERE TO BECOME AVAILABLE. THE FAILURE MILEAGE WAS APPROXIMATELY 22,000. VIN TOOL CONFIRMS PARTS NOT AVAILABLE.

NHTSA complaint #11004054 — an unverified report by a vehicle owner.