What 625 owners told NHTSA about the 2020 Toyota RAV4 Plug-in Hybrid

The contact owned a 2020 Toyota Rav4. The contact stated that while pulling into a vertical spot and making a right turn, the vehicle suddenly accelerated, jumped the curb, the sidewalk, and continued driving down the sidewalk and crashed into a building. The brake pedal was depressed but was stuck. The vehicle failed to turn off, and the parking brake failed to engage. There were no warning lights illuminated. The air bags deployed as needed. A Police report was filed. The EMS workers were unable to depress the brake pedal. The undercarriage of the dashboard ripped the skin off both shins. The contact was transported to the trauma hospital, where medical attention was provided for four weeks to close the wounds. A skin graft was performed on both legs. The vehicle was towed to a tow lot. The local dealer was not contacted. The vehicle was not diagnosed or repaired. The manufacturer was not notified of the failure. The vehicle was deemed a total loss by the insurance company. The black box data was retrieved, which showed the acceleration, but no information if the brake pedal was depressed. The approximate failure mileage was 25,000.

NHTSA ODI 11750253

In March 2025 the driver door lock stopped working electronically and would only work manually. In August 2025 the passenger door lock stopped working noisy of the time. In Dec 2025 the rear passenger side does lock stopped working most of the time.

NHTSA ODI 11745836

The front brakes wear out too quickly. In the past 3 years, the front brakes and rotors have had to be replaced 5 times while the rear brakes only once. this is not normal. i have complained to the dealership but they have no answers.

NHTSA ODI 11745179

The contact owns a 2020 Toyota Rav4. The contact stated that while driving 20 MPH and making a turn, the vehicle felt like it was going to flip over. There was no warning light illuminated. The contact stated that the dealer was made aware of the failure, but the vehicle was not repaired. The manufacturer was made aware of the issue. The contact stated that the VIN was not included in NHTSA Campaign Number: 20V373000 (Steering). The contact associated the failure with the recall. The failure mileage was approximately 74,000.

NHTSA ODI 11744881

The contact owns a 2020 Toyota RAV4. The contact stated that while driving at an undisclosed speed, the contact noticed that there was an unusual sound coming from the rear of the vehicle. The contact parked and inspected the vehicle. The contact stated that upon opening the rear passenger's side door, the contact noticed water leaking from the bottom of the door panel onto the ground. The contact stated about a gallon of water leaked from the rear passenger's side door panel. The vehicle was taken to the dealer, where the contact was informed that the repair was not covered under a recall. The vehicle was not repaired. The contact referenced an unknown recall; however, the VIN was not associated with the recall. The vehicle was not diagnosed or repaired by an independent mechanic or dealer. The manufacturer was made aware of the failure, and a case was filed. The contact was advised to take the vehicle to the dealer for inspection. The failure mileage was approximately 60,000.

NHTSA ODI 11743023

If I don't drive the car for 1 to 2 weeks, the car's 12v is completely drained of power and the care needs to be jumped, otherwise, it will not start. This is consistent. I've taken this to several Toyota dealerships and they all have reported my 12v battery is healthy. However, Toyota is aware and is charging for the fix, labelled as T-SB-0089-21. The known issue is a piece of electronics in the car that continually drains power because it does not properly shut off. This should not be a paid fix. This should be a recall. When the car is jumped and the car finally starts, it reports a message saying something about some safety features not available. The car needs to be moved every 2 weeks due to mandatory city street cleaning so at least once every month the car needs to be jumped if not used the week prior.

NHTSA ODI 11741051

The contact owns a 2020 Toyota RAV4. The contact stated that while driving, the contact observed a swishing noise coming from the rear passenger door. Upon inspecting the vehicle, the contact noticed the swishing noise when moving the door. The vehicle was taken to a dealer, where it was diagnosed that water had collected in the rear passenger door and all door seals needed to be replaced. The vehicle was not repaired. The manufacturer was not notified of the failure. The failure mileage was approximately 87,000.

NHTSA ODI 11740599

Odometer Fraud. The contact purchased a 2020 Toyota Rav4. The contact stated that it was discovered that there was a mileage discrepancy. The vehicle was a dealer sale. At the time of purchase, the vehicle mileage was 59,475. The contact stated that while his father was driving the vehicle, the vehicle stalled several times. The contact's father was a mechanic and was able to repair the vehicle. It was later discovered that Carfax reported the vehicle mileage as 176,009.

NHTSA ODI 11740650

Hinges on the trunk wore out abnormally fast causing the struts to fail and trunk to misalign causing further lift gate damage. Caused a roughly one inch gap in the trunk there light was visible and wind can be felt through. If not addressed the hinge will rip off and the trunk will go with it.

NHTSA ODI 11740174

Coolant bypass valve leak. An known issue however dealership will not pay for repairs due to vehicle having 106000 mile. 6000 over what the bulletin 24TE04 states it will cover.

NHTSA ODI 11739682

Toyota made a defective coolant valve in their 2019-2021 cars that leaked spontaneously in these vehicles. Over 950,000 cars have been affected to date, including my 2020 Rav4. They are aware of the issue and made a customer support program for this issue which led to engines overheating/electrical code problems, which can cause a severe safety issue if left unrepaired. The program however has a limitation until November 2025 or 100,000 miles whichever comes first. When I was alerted of this, I brought my car to the dealer for service, but they wouldn't replace the part because it wasn't leaking too much at the time to need repair. However, just 4 months after the primary coverage expired, my engine code went off and when I brought my car, the coolant valve turned out to be defective and leaked into the electrical wire harness which then also had to be replaced in addition to the coolant valve. The repair cost was $1200 and both were required to keep the car driving safely and reliably on the road. Because my car had 120,000 miles and the known issue presented after Nov2025, Toyota refuses to cover the service, although it is a known manufacturing defect. Toyota is committing fraud to avoid covering this safety issue. The repair is expensive and if left unrepaired, the cars can spontaneously catch on fire on highways and in parks leading to wild fires and endanger others on the road. The toyota technician specifically informed me the issue was similar to other cars and known and the defect led to the destruction of the wire harness. To avoid a safety recall, Toyota reached a private settlement against class action lawsuit and created a limited CSP to avoid covering the defect in cars like mine to maintain their reliability status in consumer reports so cars like mine with little higher mileage won't be reported. It is fraud. I believe they are skipping on consumer repair bills that consumers on entitled to for their manufacturing defect.

NHTSA ODI 11739481

The contact owns a 2020 Toyota RAV4. The contact stated that while the vehicle was parked, coolant was observed leaking from the engine compartment with no warning lights illuminated. The vehicle was taken to the dealer where it was diagnosed that the engine casing had failed, and the contact was informed that the engine needed to be replaced. The vehicle was not repaired. The manufacturer was made aware of the failure but denied the engine replacement request because the vehicle had previously been serviced by an independent mechanic for engine maintenance. The contact stated that the failure was related to NHTSA Campaign Number: 20V064000 (Engine and Engine Cooling). The approximate failure mileage was 34,678.

NHTSA ODI 11736379

I am having a failure of my liftgate. My liftgate hinges are cracked and pulling away. The welds are cracked and weak. The liftgate does not close properly. I fear my liftgate will fall off and this could cause safety concerns for other vehicles behind me as well as potential harm to passengers in the back seat. I have a call into the dealer where my 2020 RAV4 Adventure was purchased but have not heard back from them yet.

NHTSA ODI 11735771

The contact owns a 2020 Toyota RAV4. The contact stated that while driving at an undisclosed speed, the brake pedal became inoperable and nearly traveled to the floorboard while attempting to stop the vehicle. A “Pull Over” warning message was displayed. The vehicle was towed to an independent mechanic, where it was diagnosed with diagnostic trouble code C1391. The contact was informed that the brake booster and master cylinder had failed and needed to be replaced. The vehicle was not repaired. The vehicle was then towed to a dealer, where the same diagnosis was confirmed. The contact was again informed that the brake booster and master cylinder had failed and required replacement. The vehicle was not repaired. The manufacturer was made aware of the failure and referred the contact to the NHTSA hotline for further assistance. The failure mileage was approximately 106,000.

NHTSA ODI 11735908

The left rear lift gate hinge has warped in such a way the seam sealer can be seen broken and the lift gate is no longer aligned properly so its causing damage to the right side lift gate light assembly as well as the right side taillight.

NHTSA ODI 11734623

The powered liftgate hinge is cracking and coming off the body of the car. Now the trunk/liftgate will not close. This is now a safety concern as I’m afraid the other hinge is becoming overloaded and the entire thing could separate off from the car. This seems to be a common issue with my model and year. No warning of this. All of a sudden I could not close my trunk.

NHTSA ODI 11731855

The contact owns a 2020 Toyota Rav4. The contact stated while driving 40 MPH, the message "Air Bag Fault" was displayed. An independent mechanic was contacted. The vehicle was taken to the independent mechanic to be diagnosed, and it was determined that the air bag needed to be replaced. The vehicle was not repaired. The manufacturer was notified of the failure and filed a case. The approximate failure mileage was 110,000.

NHTSA ODI 11730130

Sudden and complete failure of the water pump causing an explosion of the part. While traveling down the interstate, put lives in danger due to sudden jolt and rapid deceleration. Recently brought the vehicle in to correct recall on the engine coolant bypass valve. Issue with the bypass valve hastened the deterioration of the water pump to the point of failure. Told by mechanic that this is a known issue that just happens with Toyota’s. If this is a known issue, then it seems to me there should be another recall on the water pump. Plastic parts with highly corrosive liquids at high temps do not mix. Toyota needs to fix this costly issue.

NHTSA ODI 11727069

The contact owns a 2020 Toyota Rav4. The vehicle was previously taken to a dealer for maintenance, and it was discovered that there was an oil leak underneath the vehicle. The contact stated that the transmission was shifting roughly while driving. The vehicle was driven to a local dealer, where it was diagnosed with transmission failure. There were metal fragments found in the transmission fluid. The vehicle was not repaired. The manufacturer was not notified of the failure. The failure mileage was 133,000.

NHTSA ODI 11726424

2020 Hybrid RAV4 rear liftgate failure. The vehicle has been in no accidents and has never been damaged. Initially, it was a slight misalignment in 2022 and would still latch once opened and closed, but over time, the liftgate itself became separated from the vehicle body and the hinges are visibly bent. Initially presumed the sensor was being blocked somehow as it wouldn’t close as it lowered, but over time you could visibly see the alignment was off from the vehicle body. Now the tail lights no longer line up and there is large gapping along the top of the liftgate where it should meet the body of the car. Bent hinges were confirmed at a Toyota dealership and then confirmed at a body shop as well. The body shop informed me that they have seen and repaired this exact issue multiple times and recommended checking with the service center in case of any recalls or TBs. As of 2026 before repairs, the trunk is completely unusable as it has to be forced closed after use which threatens to compromise the structure of the vehicle. If the trunk cannot be latched or opened, it poses a safety hazard as a blocked means of emergency egress as well as a safety hazard of opening on the road if no longer able to latch.

NHTSA ODI 11724983

Engine maintenance light came on. Many others are reporting the same problem. Coolant bypass hose or valve.

NHTSA ODI 11724113

Rear middle seatbelt sensor keeps going off when driving.

NHTSA ODI 11723797

The contact owns a 2020 Toyota Rav4. The contact stated that while driving at an undisclosed speed, the steering wheel failed to turn in the intended direction. No warning lights were illuminated. The vehicle was taken to an independent mechanic, where it was diagnosed with an electronic power steering module failure. The contact was advised to take the vehicle to the dealer. The contact was informed of an unknown recall; however, the VIN was not associated with the recall. The vehicle was not inspected. The contact was provided a diagnostic test fee, and the contact declined. The manufacturer was made aware of the failure, and a case was filed. The contact was informed that the repair was not covered under the recall. The failure mileage was approximately 133,255.

NHTSA ODI 11722079

I am submitting this complaint regarding a structural failure of the rear liftgate hinges on my 2020 Toyota RAV4 XLE. The liftgate began opening and closing crooked, and I noticed the door was no longer aligned evenly. After inspection by Toyota dealership, I was informed that the metal hinges attached to the liftgate and body are cracked and must be replaced. This failure is not the result of an accident, misuse, or impact. I have never been in a collision involving the rear of the vehicle. I was told this damage is considered “wear and tear,” so my insurance company declined coverage. The Toyota dealership also declined to cover the repair, stating it is not covered under warranty so I will have to pay out of pocket. However, after researching this issue, I found that many other Toyota RAV4 owners have reported the same hinge cracking and liftgate misalignment problem. This appears to be a widespread manufacturing or design defect rather than normal wear. This is a serious safety concern. If the hinges continue to crack, the liftgate could fail completely and fall, potentially causing injury. The misalignment also prevents the liftgate from opening and closing properly, which affects vehicle safety and usability. I am requesting that NHTSA investigate this issue and consider whether a safety recall or technical service bulletin is necessary to protect drivers and passengers. Thank you for your time and consideration.

NHTSA ODI 11718624

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)

NHTSA ODI 11716588