2020 Toyota RAV4 Body & structure Problems

cracking, bending, and failing liftgate hinges and struts.

NHTSA ID

11762621

Incident

Jun 1, 2023

The rear liftgate is no longer aligned and does not sit evenly when closed. After noticing the uneven fit, I inspected the liftgate hinges and found that both metal hinge brackets appear to be cracking and splitting at their mounting points. There were no warning lights or messages before the problem appeared. I am concerned that the hinges could fail completely, causing the liftgate to fall unexpectedly, detach from the vehicle, or create a road hazard while driving.

NHTSA ID

11762068

Incident

Sep 4, 2026

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 ID

11743023

Incident

May 22, 2026

Mileage

60,000 mi

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 ID

11740599

Incident

Jan 15, 2026

Mileage

87,000 mi

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 ID

11740174

Incident

Feb 1, 2026

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 ID

11735771

Incident

Sep 27, 2025

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 ID

11734623

Incident

Dec 16, 2025

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 ID

11731855

Incident

Apr 17, 2026

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 ID

11724983

Incident

Sep 27, 2022

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 ID

11716588

Incident

Jan 15, 2026

Rear hatch were repaired new actuators but still malfunctioning now hinges are defective dealer won't honor extended warranty suggest take to body shop have defective hinges replaced at my cost

NHTSA ID

11714677

Incident

Jan 14, 2026

The door lock actuators required repair on all my doors for the RAV4 2020. They stopped working after the 3 year warranty was up. This is a safety issue. I had to manually lock and unlock my doors, which left in a dangerous position at night. Over the course of a year all 4 doors needed to have the actuators replaced. This happrened in 2024.

NHTSA ID

11702215

Incident

Dec 2, 2024

The paint on my 2020 Toyota RAV4 (Blueprint color) is peeling and deteriorating prematurely, on the hood. The vehicle has been properly maintained and has not been in any accidents. The paint started peeling without any external cause. I’ve noticed similar complaints from other 2020 Toyota RAV4 owners, especially those with the Blueprint color, reporting the same issue. This suggests a widespread paint or clear coat defect from the manufacturer. The peeling paint not only affects appearance but also exposes the metal body to rust and corrosion, which could eventually compromise the vehicle’s safety and structure. Toyota has not issued a recall or offered repairs for this known problem, and many owners are being asked to pay out of pocket for costly repainting. I am requesting that NHTSA investigate this issue as a potential manufacturing defect and urge Toyota to take corrective action through a recall or warranty extension for affected vehicles.

NHTSA ID

11698785

Incident

Sep 1, 2025

The hinges for the rear door/hatch broke. The door became unaligned and would not close and I had to drive my vehicle to a repair shop with the rear door ajar. This has not been inspected by manufacturer, no police or insurance inspection either. There is no reason these hinges should be worn and literally torn after 5 years.

NHTSA ID

11680127

Incident

Aug 10, 2025

The contact owns a 2020 Toyota Rav4. The contact stated that during inclement weather, moisture entered the vehicle through the front passenger side and the rear driver side doors. The contact stated that upon opening both the front passenger’s and the rear driver’s side doors, there was a water swishing sound coming from inside the doors. The vehicle was not diagnosed or repaired. The manufacturer was not notified of the failure. The failure mileage was approximately 58,000.

NHTSA ID

11679756

Incident

Jun 1, 2025

Mileage

58,000 mi

Lift gate will not close properly. Hinges a top of gate are coming undone. Worried gate will open while driving. Had to manually close and hope it closed.

NHTSA ID

11666283

Incident

Jan 24, 2025

Liftgate hinges on my 2020 RAV4 hybrid XSE failed, causing misalignment so the liftgate/tailgate does not close properly or completely. Liftgate hinges are made of materials that are not strong enough for consistent and safe operation. Toyota has not issued a recall or provided safety warnings or notifications, nor is the company providing replacement hinges. RAV4 owners are left to pay for the replacement of these hinges when it’s a quality issue that can impact the safe operation of 2020 Toyota RAV4s. Toyota recently settled a lawsuit brought by an individual because of this issue.

NHTSA ID

11649073

Incident

Mar 1, 2025

Power lift gate not opening and shutting then noted that the mount on the passenger side is partially sheared off the car bracket and starting to separate on the drivers side. Was unable to close the hitch all the way, and beeping continuously while driving so brought to a toyota dealer service who ordered replacement pistons, in the mean time battery died due to being unable to close back. Once piston parts were obtained by toyota service center, had to have the car towed due to battery not able to be charged, then they noticed the bolts starting to shear off. Stated they have never seen anything like this but when looked online, found this has been a common problem and a class action suit has been filed for this exact reason

NHTSA ID

11646164

Incident

Feb 21, 2025

The contact owns a 2020 Toyota Rav4. The contact stated that while the vehicle was parked, the contact inspected the vehicle and became aware that the hinges on the rear liftgate were bent, and the liftgate was misaligned. The vehicle was not taken to a dealer or independent mechanic to be diagnosed or repaired. The manufacturer was notified of the failure but offered no assistance. The contact was informed that there was no recall on the VIN for the failure. The approximate failure mileage was 22,500.

NHTSA ID

11635726

Incident

Jan 11, 2025

Mileage

22,500 mi

right rear hinge for hatchback failed and making my hatchback unusable. I have been on several websites and this common issue it seems for Rav 4. Toyota will not fix it.

NHTSA ID

11634306

Incident

Jan 6, 2025

The Rear Hatch started to get stuck. It is automatic so you would normally press a button to open and close and it would slowly move up or down and close shut on its own. When the issue started, it would "pop open" but stay stuck to a point where I would need to manually lift it open. (hitting my head on it often) Right before I took it to the dealership service, it would not close properly. While it seemed close, the notification showed it open therefore, not allowing me to lock my car and the lights on the car would need to stay on while car was parked and off. Driving home, the "open door" notification was beeping non-stop. Once again I had to open and close manually until it was considered "closed" Brought the car into the Toyota Dealership to assess. They found that the power lift gate hinges on the door were coming off and it needs to go to an Auto Body for realignment. I performed research online and found this to be a very common issue with the Toyota RAV4's. I have had leased 2 RAV4's prior to this one and never had a problem (those were manual hatches) [XXX] [XXX] My car has 33k miles on it although this issue (not as severe) started a while ago. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11631836

Incident

Dec 19, 2024

The hinges on the lift gate are detaching causing my trunk not to close all the way.

NHTSA ID

11629470

Incident

Dec 8, 2024

What component or system failed or malfunctioned, and is it available for inspection upon request? THE HINGES ARE BROKEN ON THE HATCH How was your safety or the safety of others put at risk? MY SAFETY AS WELL AS OTHERS IS PUT AT RISK BECAUSE THE HINGE IS BROKEN. THE HATCH WILL NOT CLOSE THEREFOR COULD FLY OFF WHILE DRIVING Has the problem been reproduced or confirmed by a dealer or independent service center? THE ISSUE WAS TAKEN TO A DEALERSHIP BUT THEY FOUND NO PROBLEM, ANOTHER APPOINTMENT SCHEDULED TUESDAY10/22 Has the vehicle or component been inspected by the manufacturer, police, insurance representatives or others? NO Were there any warning lamps, messages or other symptoms of the problem prior to the failure, and when did they first appear? NO This is not a rare issue. I have seen dozens upon dozens of articles on Google, Facebook and Reddit of others dealing with the same exact issue. Examples: [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11620804

Incident

Oct 19, 2024

This vehicle is equipped with a power back door (PBD) that has begun to malfunction. March 29, 2024 was the first occurrence of the PBD malfunction when the opened back door would not fully close after clicking the appropriate button on the electronic key switch. There were no warnings that preceded the malfunction. The PBD would only close the back door a few inches before stopping. Additional clicks only closed it a few more inches and manual closing (requiring significant pressure) was required to fully close the door. Additional random occurrences of this PBD malfunction have happened over the past six months and have now become so frequent that on September 30, 2024 I turned off (via the multi-information display) the PBD function and must now resort to fully manual opening and closing of the back door. Based on multiple other complaints filed with NHTSA for this particular vehicle (2020 Toyota RAV4; NHTSA ID Numbers 11572353, 11572802, 11573768, 11579590, 11585733), I inspected the edges of the back door, the body's back door cavity, and the two back door spindles for damage, foreign objects, dirt, etc. that might impede PDB operation and found none. I also inspected the two back door hinges and saw no damage, no warping, no corrosion, and no movement of the hinges from their original installation locations. This PBD malfunction affects safety as the force required to manually open and close the back door is significant and operation of the back door might be impossible for people not physically able to effect the force needed. The vehicle is available for inspection and has not yet been inspected by the Toyota dealer where I purchased the vehicle in August 2020 or by others.

NHTSA ID

11617360

Incident

Mar 29, 2024

The contact owns a 2020 Toyota Rav4. The contact stated that while the vehicle was parked, the passenger’s side rear side door became flooded after inclement weather. The contact stated that while attempting to open the door, there was a slushing sound coming from the door. The vehicle was not taken to be inspected. The vehicle was not repaired, and the failure persisted. The manufacturer was notified of the failure. The failure mileage was 68,000.

NHTSA ID

11616603

Incident

Sep 1, 2024

Mileage

68,000 mi