2015 Toyota Sienna Body & structure Problems

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 ID

11713421

Incident

Oct 1, 2025

See attached document for complaint.

NHTSA ID

11692382

Incident

Sep 18, 2025

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 ID

11676320

Incident

Feb 22, 2025

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 ID

11663672

Incident

May 29, 2025

Mileage

117,000 mi

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 ID

11550327

Incident

Oct 15, 2023

sunroof exploded while driving

NHTSA ID

11436200

Incident

Oct 7, 2021

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

NHTSA ID

11353820

Incident

Sep 8, 2020

Mileage

410,000 mi

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 ID

11348896

Incident

Aug 11, 2020

Mileage

94,000 mi

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 *TR

NHTSA ID

11337372

Incident

Jun 12, 2020

Mileage

47,000 mi

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 ID

11246523

Incident

Aug 25, 2019

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). *TT

NHTSA ID

11243729

Incident

Jul 30, 2019

Mileage

20,000 mi

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 ID

11243071

Incident

Jul 2, 2019

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 ID

11218558

Incident

Jun 3, 2019

Mileage

23,350 mi

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 ID

11207681

Incident

Jan 7, 2019

Mileage

71,000 mi

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 ID

11192813

Incident

Feb 15, 2019

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 ID

11172122

Incident

Jan 1, 2019

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 ID

11153109

Incident

Nov 21, 2018

Mileage

51,000 mi

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 ID

11123569

Incident

Aug 30, 2018

Mileage

100,000 mi

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 ID

11110189

Incident

May 1, 2017

Mileage

30,000 mi

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 ID

11074894

Incident

Nov 22, 2016

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

NHTSA ID

11021973

Incident

Jan 1, 2017

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 ID

11032817

Incident

Sep 5, 2017

Mileage

28,650 mi

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 ID

11025374

Incident

Mar 1, 2017

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*JS

NHTSA ID

11012193

Incident

Jan 4, 2017

Mileage

16,000 mi

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 ID

11010986

Incident

Jan 10, 2017

Mileage

30,000 mi