2004 Toyota RAV4

Rear suspension control arm assembly (that supports the springs, control arm rods, shocks, as well as the the hub, brakes and wheel ) breaks completely due to rust and corrosion. It is a poor design that you can see this would happen at the weakest and narrowest section of the part. This causes the entire wheel assembly to drop or twist off, as it did mine and fortunately not on highway however on a busy local road. This vehicle was bought in [XXX], but original owner primarily had it in [XXX] where I can understand there was lots of salt on the road during snow time. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11753960

Incident

Jul 19, 2026

The inspection sticker mechanic inspected the car and found the rear brake hoses rubbing against the sway bar indicating that there should be a clip somewhere to prevent rubbing. See picture attached. See if a possible safety recall can be done on all Toyota RAV4 vehicles.

NHTSA ID

11742160

Incident

Jun 4, 2026

I have 2003 registered as 2004.This vehicle that I has Manufactured November 2003 base on the sicker beside driver side door and it's been registered as 2004 .Now the problem that I have is slow moving to first gear suddenly jump to second gear (This is Automatic Trnasmission) I thought it was accelerator pedal issues but I replace the pedal and its the same not shifting properly.I cannot drive my car now due to shifting issue in first anf second gear.This my second Rav4 .I have 2001 toyota Rav4 all wheel drive I I have the same Issue not shifting properly first and second gear ,I purchase ECM module back in 2021,2022 amount of $775.00 at Toyota Parts Deal.com that is not calibrated and I pay $350 at DCH toyata in Torrance for calibration I bring this issues at BAR in 2021 ,2022 to reinburstment of the money to Toyota Headquaters until now no response .I need your help to resolves this Issues. I work Winston Tire and Firestone tire And I studies Automotive system at SCROC in Torrance,Ca. 90505 Diploma, profile.I need my money back for the 2001 toyota Rav4 and I need your help for this 2003,2004 transmission issues that I have right now .My 2001 toyota Rav4 has no issues in shifting since I purchase the ECM module.I currently own this 2 vehicle registered under my name.Thank you for kind Consideration, Respectfully yours [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11733766

Incident

Apr 9, 2026

I was driving on a highway, there was a red light and I pressed on the brakes. The car kept going forward, the brakes became resistant to any pressure and the car continued to roll forward. There were no warning lights when the car was started or during the incident. I kept trying to brake the car, but the car kept moving forward and was about to hit the car in front of me. The cars around me started honking, trying to move out of the way; Luckily the light turned red and the car in front of me was able to move out of the way. I could not press on the gas or the break, I decided to turn the ignition off and the car was able to turn off. I re-started the car and then was able to go again. Had this been on the highway and I was moving at a faster speed, I probably wouldn't be typing this right now and would be in the ER with potentially others. This is the second time an issue like this happened. The first time the car was in reverse and it wouldn't brake and I almost slammed into the car behind me. The brakes and gas were not responsive. I took it to a mechanic right away, got new brakes, rotors, engine and transmission was checked. A couple months later this happened again.

NHTSA ID

11622621

Incident

Oct 29, 2024

10 days ago transmission on 2004 Rav started to act funny. Slow/jerky to engage in lower gears. Check engine lights came on. Checked out by mechanic who said it looked like a transmission problem and should have it looked at by transmission specialist who said it was not safe to drive as is since it could simply die at any time, and it needed a new transmission. When replacing trans, the trans man found the ECM had to be replaced. He said this often happened with 2003 thru 2005 RAV4s. On looking through your site, discovered others had similar issues with their 2004 Ravs. I also found out that the electronic control module for these vehicles is defective and must be repaired to correct the transmission issues. What did Toyota have to say when you looked into this, or do you not think it’s a safety issue?

NHTSA ID

11610035

Incident

Aug 11, 2024

The transmission slips suddenly, even during highway driving conditions, which almost resulted in a terrible crash. I found out that the electronic control module for these vehicles is defective and must be repaired to correct the transmission issues.

NHTSA ID

11503509

Incident

Jan 23, 2023

The TRAC system which brakes the car when it senses the wheel loosing traction hits the breaks on curves, even when turned off. It is random. It is not part of the inspection. When the streets are rain slick it has caused my car to skid out of the lane I was in. It has not been reproduced by anyone as I have not turned the car in to an independent dealer or mechanic. This vehicle has not been inspected by manufacturer, police, insurance representatives or others. The TRAC light comes on and beeps when the car breaks.

NHTSA ID

11490185

Incident

Oct 19, 2022

GOOD AFTERNOON! I JUST NOTICE TODAY THE REAR SUSPENSION IS VERY RUSTY. I WOULD LIKE TO KNOW IF IS ANY RECALL IN THIS CAR. THANKING IN ADVANCE FOR HELPING IN THIS MATTER.

NHTSA ID

11340252

Incident

Jul 19, 2020

To prevent brake rotor rust from forming during transportation and storage, wheel film will be used instead of a cardboard type of anti-rust cover. The purpose of the wheel film is to shield the disc brake rotor from weather elements and initial rust before the vehicle is delivered to the customer. Consequently, the film should remain on the wheel for as long as possible.

The condition known as acid rain is caused by airborne chemicals or particles in the atmosphere, which mix with rainwater, nighttime dew, or high humidity to form acidic compounds. If these contaminants settle and remain on a painted vehicle surface, especially the horizonal areas of the hood, roof, and decklid, significant damage can occur. This damage is the result of actual etching of the paint and appears as pitting or water spots. As acid rain droplets on the vehicle surface evaporate, the concentration strength of the acid increases, causing deeper and more rapid damage. This evaporation and corrosive action also occur more rapidly on dark colored cars as direct sun heat increases. It is the dealer’s responsibility to protect and maintain the quality of the vehicle’s paint finish after receipt at the dealership prior to the first sale. In areas known for high frequency and/or concentration of acid rain, frequent vehicle washing during high heat or humidity periods will minimize the potential for paint damage caused by acid rain. It is further recommended that either reverse osmosis or deionized water be used to prevent water spotting.

Acid rain results from rainwater or other airborne moisture that become acidic due to industrial chemical impurities in the atmosphere. If these acidic compounds settle on an exposed vehicle, especially the horizontal areas such as the hood, roof, and decklid, significant damage to the painted surfaces can occur. Acid rain damage can typically be identified on vehicles by the presence of stains on the paint surface that resemble hard water spots. Unlike water spots however, acid rain damage cannot be removed by regular washing procedures. Also, because acid rain can etch and soften the paint, normal buffing or polishing repair procedures should not be attempted. This can cause further damage and result in visible depressions in the paint surface. The following are the three major categories of acid rain damage: •Minor damage: requires only buffing to repair. •Moderate damage: usually requires neutralizing, color sanding, and buffing. •Severe damage: extending beyond 1/2 mil of clearcoat on a pearl, metallic, or solid color, requires neutralization, sanding, and repainting. In cases where acid rain damage is minor, neutralization and buffing with a liquid-type paint finessing product may provide an adequate repair. Only specially formulated products outlined in this bulletin should be used for that purpose. Unfortunately, other than minor damage, there is no simple method of determining the actual extent (depth) of acid penetration other than color sanding a representative affected area until there is no visible etching or depressions, followed by measuring the amount of paint removed with either a magnetic or digital-type film thickness gauge. The procedures in this bulletin are intended for use by qualified body/paint technicians and should not be attempted by inexperienced personnel. It is the dealer’s responsibility to protect and maintain the quality of the vehicle’s paint finish after receipt at the dealership prior to the first sale. Perform frequent vehicle washing, as often as daily, during high heat and humidity periods to minimize the potential for paint damage due to acid rain exposure. This is especially important in geographical areas known for high frequency and concentration of acid rain and industrial fallout.

Toyota vehicles are currently protected with RapgardTM protective film designed to protect the horizontal painted surfaces. This material protects from acid rain, environmental fallout, and rail contamination. Follow the Removal Procedure in this bulletin to remove the RapgardTM protective film within 90 days from initial application.

Vehicles may occasionally be subjected to contamination by airborne iron particles shed from railroad tracks, train wheels, exposure to heavy machinery facilities, grinding, welding, etc. This type of contamination can be identified by the presence of small, red or brown particles on the paint surface. These particles are often difficult to see on dark color paints but can be easily felt when brushing a hand across horizontal body surfaces such as the hood, roof, or deck lid. Follow the Repair Procedure in this bulletin to clean vehicles that may have been subjected to contamination by airborne iron particles such as rail dust during rail transportation or extended storage near industrial areas.

To prevent brake rotor rust from forming during transportation and storage, wheel film will be used instead of a cardboard type of anti-rust cover. The purpose of the wheel film is to shield the disc brake rotor from weather elements and initial rust before the vehicle is delivered to the customer. Consequently, the film should remain on the wheel for as long as possible.