What 233 owners told NHTSA about the 2016 Toyota RAV4 Hybrid

Vehicle: 2016 Toyota RAV4 Color: Factory Super White / Blizzard Pearl (whichever applies) I am filing a complaint regarding a well-known latent manufacturing defect involving peeling factory paint on my 2016 Toyota RAV4. The original factory-applied white paint is peeling and delaminating from the exterior metal body panels under normal use and maintenance conditions. The paint failure appears unrelated to any accident, impact, misuse, neglect, or environmental damage. The failed component is the factory-applied exterior paint and coating system on the vehicle’s metal body panels. The affected areas are available for inspection upon request. The paint is separating from the primer/base layer and peeling off in sheets, exposing underlying surfaces and creating risk of corrosion and reduced vehicle value. Toyota has publicly acknowledged widespread issues involving “Super White (040)” and “Blizzard Pearl (070)” paint on numerous Toyota models, including RAV4 vehicles, through Customer Support Program ZKG and multiple Technical Service Bulletins. Toyota documents specifically state the issue involves paint adhesion failure during the manufacturing process causing peeling on exterior metal body panels. This issue creates safety concerns because exposed metal surfaces may eventually corrode or rust, reducing long-term structural integrity and potentially creating visibility distractions while driving as paint continues to separate and peel unexpectedly. Large peeling sections can also detach while driving and create roadway debris hazards for other motorists. The condition has been widely reported by consumers across online forums, complaint databases, and dealerships for many years. Numerous owners of white Toyota vehicles have reported identical failures involving factory paint peeling and delamination. The problem has been visually confirmed by dealership personnel / independent body shop personnel (modify if applicable). And they have refused to cover it at all

NHTSA ODI 11739542

While shopping at the grocery store, I experienced an incident upon leaving the parking lot. After reaching my first red light, I noticed smoke rapidly billowing from under the hood of my vehicle. My husband, who was driving behind me, immediately saw the smoke and instructed me to pull over. Once I stopped, he asked me to pop the hood. Upon opening it, he urgently removed his shirt to try and extinguish the fire. The damage was extensive — a hole burned through the hood, significantly compromising the vehicle’s crash safety rating. Additionally, melted plastic covered the battery area, and the radiator hose was damaged, rendering the vehicle unsafe to drive.

NHTSA ODI 11657186

Headlights are cloudy to the point of dimming the visibility of the light. When I asked the dealer, they could not clean headlight apparatus. I also cannot clean the buildup as it is on the inside of the headlight cover. I feel that this is a defective part that could potentially be the cause of an accident.

NHTSA ODI 11610915

My car has an electric rear door/hatch. Without electric it is extremely difficult to open. The electric opening does not work so I had to have it repaired. The cost was about $1100. The Toyata repair shop mechanic said there have been many of these repairs. The vehicle is only 6 or 7 years old.

NHTSA ODI 11496327

While going about 60 mph in a highway curve, the rear passenger door partially opened (unlatched). The driver dashboard immediately started flashing warning triangle and door opened picture. After stopping on a shoulder, I went outside and saw the door partially opened. After opening/closing the door no more errors occured.

NHTSA ODI 11465167

I was driving down a highway on the afternoon of February 26, 2022, when we heard a loud pop. At our next stop, we pulled back the interior sunroof cover and discovered the sunroof had shattered spontaneously. It was buckled up, not down, so I don't believe anything on the highway hit the vehicle. We were very lucky the interior cover was closed at the time it happened, or it's possible glass could have fallen into the car on the driver or passenger.

NHTSA ODI 11454473

MY BRAND NEW CAR CAUGHT FIRE IN THE FRONT WHILE IT WAS PARKED OUTSIDE A RESTAURANT. I CAME OUTSIDE TO LEAVE AND IT WAS TOWED AWAY. THE CAR WAS TOTALED FROM THE FIRE. I SAW THE RAV4 INVESTIGATION IS HAPPENING AND WANTED TO MAKE SURE YOU HAD MY REPORT INCLUDED. THE FIRE HAPPENED IN THE FRONT LEFT (AS IT WAS STATED IN THE ARTICLE OTHER CARS). I CAN SEND YOU ADDITIONAL DETAILS IF NEEDED BUT EVERYTHING IS MATCHING UP WITH THE OTHER INCIDENTS. IT WAS A BRAND NEW CAR WHICH IS WHY IT WAS SUCH A STRANGE EVENT.

NHTSA ODI 11398858

TL* THE CONTACT OWNS A 2016 TOYOTA RAV4. THE CONTACT STATED THAT HE NOTICED MOISTURE COMING FROM THE FLOOR ON THE FRONT PASSENGER'S SIDE OF THE VEHICLE. THE CONDITION WAS NOTICEABLE AFTER IT RAINED OR WHEN THE AIR CONDITIONER WAS BEING USED. THE VEHICLE WAS TAKEN TO THE DEALER LONGO TOYOTA 3534 N. PECK RD., EL MONTE, CA 91731, (626) 539-2403. THE MECHANIC WAS UNABLE DIAGNOSE THE ISSUE SINCE THE FLOOR AREA WAS DRIED. IT WAS SUGGESTED TO THE CONTACT TO BRING THE VEHICLE BACK ANOTHER TIME. THE VEHICLE WAS RETURNED TO THE DEALER AND DIAGNOSED THAT THE AIR CONDITIONING DRAIN HOSE UNDERNEATH THE FLOOR WAS CLOGGED WITH SPIDER WEBBING. THE FLOOR UNDERNEATH THE CARPET WAS COVERED IN MOLD AND MILDEW DUE TO THE MOISTURE. THE CONTACT WAS CONCERNED ABOUT A HEALTH RISK FROM THE MOLD AND MILDEW. THE DEALER QUOTED A REPAIR COST OF $4,000 TO $5,000. THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS 19,000.

NHTSA ODI 11364685

TL* THE CONTACT OWNS A 2016 TOYOTA RAV4. THE CONTACT RECEIVED NOTIFICATION OF AN UNKNOWN RECALL REGARDING THE STRUCTURE. THE CONTACT STATED THAT THE MANUFACTURER EXCEEDED A REASONABLE AMOUNT OF TIME FOR THE RECALL REPAIR. PINE BELT SUBARU (1104 NJ-88, LAKEWOOD, NJ 08701, (732) 719-4521) WAS CONTACTED AND CONFIRMED THAT THE PARTS WERE NOT AVAILABLE FOR THE RECALL REMEDY. THE MANUFACTURER WAS MADE AWARE OF THE ISSUE AND WAS NOT ABLE TO CONFIRM WHEN THE PARTS WERE TO BECOME AVAILABLE. THE CONTACT HAD NOT EXPERIENCED A FAILURE.

NHTSA ODI 11253256

HELLO, MY SUNROOF SHATTERED WITHOUT WARNING. ONE MORNING, I DECIDED TO OPEN MY SUNROOF. WHEN I PRESSED THE OPEN BUTTON, THE SUNROOF MADE A CRACKING NOISE THAT GOT WORSE AS THE SUNROOF OPENED. I WAS ON A RESIDENTIAL STREET AT THE TIME. TEMP: ABOUT 65 DEGREES.,OVERCAST.

NHTSA ODI 11155604

WHEN IT RAINS THE DRIVER SIDE FLOORING AND MATS ARE COMPLETELY SOAKED ABSORBING UP TO 1 INCH OF WATER. THE CAR ISN'T DRIVEN MUCH SO THE PROBLEM ONLY STRUCK A BELL THIS YEAR. *JS

NHTSA ODI 11129655

TL* THE CONTACT OWNS A 2016 TOYOTA RAV4. WHILE THE VEHICLE WAS STATIONARY, THE AUTOMATIC LIFTGATE CRASHED DOWN ONTO THE CONTACT, WHICH CAUSED INJURY AND DISCOLORATION TO THE CONTACT'S SPINE. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS 25,000. ..UPDATED 03/09/17 *BF CONSUMER STATED SHORTLY AFTER INJURY TOYOTA ISSUED A "LIMITED SERVICE CAMPAIGN" TO REMEDY OR REPLACE THE POWER BACK DOOR ECU (ELECTRONIC CONTROL UNIT). UPDATED 7/16/18*JB *TR

NHTSA ODI 10929666

THIS SAFETY ISSUE WHICH I HAVE SEEN MENTIONED BY MANY OTHER BUYERS ONLINE AND HAVE PERSONALLY SEEN ON A 2015 RAV4 CONSISTS OF TWO PIECES OF PLASTIC MOLDING ON THE DASH BOARD WHICH APPEAR TO BE DESIGNED TO LOOK LIKE SHINY METAL MOLDINGS BUT EXHIBIT A VERY DANGEROUS GLARE FROM BOTH THE FRONT AND SIDE REFLECTIONS FROM THE SUN. EVEN WHEN WEARING SUNGLASSES IT CAN MAKE IT DIFFICULT TO SEE WHERE YOU ARE GOING. I SHOWED THIS ISSUE TO THE SALESMEN AND HE COULD SEE IT TOO. HE SAID THAT HE WOULD TRY AND FIND THE PHONE NUMBER FOR A TOYOTA REPRESENTATIVE AND CALL HIM ABOUT THE PROBLEM. AFTER NOT HEARING BACK FROM HIM I RETURNED A FEW DAYS LATER AND HE TOLD ME THAT NO ONE AT THE DEALERSHIP COULD LOCATE HIS NUMBER. HE THEN TALKED TO HIS MANAGER AND RETURNED TO TELL ME THAT HIS MANAGER WOULD SEND AN EMAIL TO THE REGIONAL REPRESENTATIVE TO SEE IF ANYTHING COULD BE DONE ABOUT THE PROBLEM. IT HAS BEEN MANY WEEKS NOW AND I HAVE NOT HEARD BACK FROM ANYONE ABOUT RESOLVING THIS SAFETY ISSUE.

NHTSA ODI 10906056

THE SUNROOF EXPLODED WHILE DRIVING DOWN THE HIGHWAY. NO ROCK WAS SEEN BEFORE IT HAPPENED AND THE GLASS WAS CURVED OUTWARD WHEN WE STOPPED TO LOOK AT IT. FORTUNATELY, THE VISOR/COVER WAS BELOW IT SO THE GLASS SHARDS DID NOT SPRAY INTO OUR FACES. IT SOUNDED LIKE A BOMB WENT OFF. THIS IS EXTREMELY DANGEROUS AND WE HAVE NO OPTION BUT TO HAVE THE SUNROOF REPLACED. IT WOULD BE WISE TO ALWAYS DRIVE WITH THE SUNROOF COVER OVER THE GLASS TO PROTECT YOURSELF.

NHTSA ODI 10860191