Huge win for car owners! All TSBs to be made public. The Center for Auto Safety just made the NHTSA (US Government) make public the full text of all TSBs from now on. They are the same organization that has petitioned the NHTSA & filed lawsuits to protect car owners over exploding gas tanks & other major safety issues. Whenever you drive in your car, you are safer thanks in part to a lot of work over the years by this small but very effective consumer advocacy group.

Please take a moment & say thank you by donating $5 or whatever you can to the Center for Auto Safety.


really awful
Crashes / Fires:
0 / 1
Injuries / Deaths:
10 / 0
Average Mileage:
86,629 miles

About These NHTSA Complaints:

This data is from the NHTSA — the US gov't agency tasked with vehicle safety. Complaints are spread across multiple & redundant categories, & are not organized by problem.

So how do you find out what problems are occurring? For this NHTSA complaint data, the only way is to read through the comments below. Any duplicates or errors? It's not us.

2004 Toyota Sienna body / paint problems

body / paint problem

Find something helpful? Spread the word.
Get notified about new defects, investigations, recalls & lawsuits for the 2004 Toyota Sienna:

Unsubscribe any time. We don't sell/share your email.

2004 Toyota Sienna Owner Comments (Page 5 of 13)

« Read the previous 20 complaints

problem #179

May 302007

Sienna 6-cyl

  • 70,000 miles


The first incident is that the passenger side sliding door started to rub the paint off the body, so we disabled it since the dealer said it was out of warranty and would cost us $1800. A couple years later the driver side sliding door seized and wouldn't close. I had to drive to where my wife and kids were stranded and cut the door's cables, so she could drive home. A couple years after that I receive an extended warranty letter from Toyota for their sliding doors, however, since there is a 120,000 mile stipulation and ours had more miles than that they said sorry we are out of luck. Toyota extended the warranty because they knew there was a problem with their sliding doors, but set stipulations, like mileages, so many people could not take advantage!!! I also had a problem with the driver's door hinge weld breaking, the dealer once again told me there was no recall and it would cost me a few hundred dollars to weld it back together. After looking at the hinge's weld I could tell it was an assembly misstake. Since I know how to weld I removed the door myself and re-welded the hinge. Several months after fixing it myself I found out there was a recall.

- Victor, NY, USA

problem #178

Feb 012013

Sienna 6-cyl

  • 150,000 miles
The 2004 through 2010 Toyota Sienna models have a known defect in the cable assembly of the power sliding doors. My 2004 Sienna has the same problems as numerous other vehicles with a loud grinding noise on the passenger side power sliding door due to a fraying cable that makes it impossible to operate the door or exit the vehicle in an emergency. Toyota has taken the step to extend the warranty on sliding doors but only to 9 years or 120K miles whichever comes first. This is a known manufacturing defect and a safety issue that should be dealt with by issuing a full recall rather than extending the warranty. Quoted repairs from my local Toyota dealer were around $1500. These repairs are covered only for those who the extended warranty is in effect. Please NHTSA order Toyota to issue a full recall on 2004-2010 Toyota Sienna power sliding doors.

- Salem, OR, USA

problem #177

Nov 152012


  • 140,000 miles
The contact owns a 2004 Toyota Sienna. The contact stated that the front driver's side door would exhibit a loud pop when being opened. The contact inspected the vehicle and noticed that the welding was fractured. The manufacturer was made aware of the failure. The vehicle was not repaired. The approximate failure mileage was 140,000. The VIN was not available.

- Monahans, TX, USA

problem #176

Jul 082010

Sienna 6-cyl

  • 25,000 miles


The contact owns a 2004 Toyota Sienna. The contact noticed that the entire dashboard was cracked. The vehicle was taken to an authorized dealer for inspection where the failure was not diagnosed. The vehicle had not been repaired. The manufacturer was notified of the problem. The approximate failure mileage was 25,000. Updated 8/26/13

- Ponkno Beach, FL, USA

problem #175

Feb 042013

Sienna 6-cyl

  • 50,000 miles
During opening and closing the front door on driver side, it makes a loud popping noise.

- Port Orchard, WA, USA

Search for these popular complaint phrases...

problem #174

Mar 082013


  • 131,432 miles
Upon pressing the open button on the remote for the passenger side sliding rear door, it makes noise but does not open. Upon further investigation we realized the cable had frayed and the door got jammed half way open. We took it to the dealership and were told to ask for an exception but because it was not completely broken they would not fix it! this poses a safety issue as the only exit for rear passengers is now the drivers side rear door until it breaks as well. Research suggests we are just barley over and only months beyond the extended warranty service for this defect @ 120K or 9yrs, leaving us to absorb the entire 1500-1800$ cost associated with repair.

- Redmond, OR, USA

problem #173

Sep 032012

Sienna 6-cyl

  • miles


Upon trying to open the manual, rear sliding door on the driver's side, it only open a few inches. Almost felt like it was hitting something, preventing it from fully opening. Took it to a local, reputable mechanic, who tried to "feel" if anything was stuck in the track. Did not see or feel anything in the track. After reading several Toyota blogs, including this site, it seems that a safety feature has malfunctioned. There is a safety feature which prevents the door from opening completely when the fuel door is open. The mechanic said that the entire door would have to be taken off, accessing it by removing the center seats and going in from the opposite sliding door. A costly job. This is apparently a manufacturer defect. I have two 9 year old boys, and if we were involved in a accident, one of them would not be able to get out from his side...this poses a great danger to my child. This needs further investigation by the and a recall issued by Toyota!

- Staten Island, NY, USA

problem #172

Aug 312012

Sienna 6-cyl

  • miles
The driver door makes a double clicking sound either on opening or closing. Tried putting DW40, but did not work. After "googling" the problem, discovered that many other Toyota Sienna owners have the same problem. It seems an issue with the way the welding is done on the door. Some bloggers have said that the dealer fixed it at no charge. Others state that the dealer and/or Toyota will not address the issue because the vehicle is outside the warranty. My deepest fear is that many drivers have stated that the door has not opened at all and that they need to exit the car from the passenger side. This is obviously a manufacturers defect and definitely poses a danger if the driver cannot exit the car, especially if there is an emergency. Thank you!

- Staten Island, NY, USA

problem #171

Mar 082013

Sienna 6-cyl

  • 120,000 miles
Upon pressing the open button on the remote for the passenger side sliding rear door, there was alot of grinding and screeching and the door only opened partially. Upon further investigation we realized the cable had snapped and the door got jammed half way open. After some considerable effort we were able to close the door manually but it was for the last time. The door is now stuck closed and is completely inoperable. This poses a safety issue as the only exit for rear passengers is now the drivers side rear door until it breaks as well. Research suggests we are just a few miles over and only months beyond the extended warranty service for this defect @ 120K or 9yrs, leaving us to absorb the entire 1500-1800$ cost associated with repair.

- Independence, MO, USA

problem #170

Nov 232012

Sienna 6-cyl

  • 84,000 miles
Driver side door won't open all the way and the driver side window won't go all the way down. Toyota extended the warranty for a known defected weld however this warranty is for a 5 year term or 100K mile for an very important part of the car. Because the window won't go down to pay tolls I must open the door. The may cause a dangerous situation. Toyota short changed any owner of this vehicle by not recalling the vehicle for this defect.

- Blauvelt, NY, USA

problem #169

Jun 162004


  • 30 miles


The contact owns a 2004 Toyota Sienna. The contact stated that the doors were too heavy for the vehicle and began to fall off the hinges. The doors would also freeze and could not be opened when it was snowing or there was freezing rain. The sliding door could not be opened electronically or manually. The vehicle was taken to a dealer and the contact was informed that the sliding door sub-control assembly would need to be replaced. The manufacturer was notified of the failure and advised that they would return her call at a later date. The vehicle was not repaired. The failure mileage was 30 and the current mileage was 119,350.

- Chicago, IL, USA

problem #168

Feb 032013

Sienna 6-cyl

  • 152,000 miles
Our 2004 Toyota Sienna minivan was parked. I opened the passenger side rear sliding door remotely with the key fob. I instantly heard a popping/crunch noise, and heard it again when I closed the door. I discovered that the exterior cable that controls the sliding motion of the door had frayed and the plastic sheathing of the cable was gone. The Toyota dealer (instantly familiar with the problem) advised that I would have to replace both the cable and the motor for a cost of $1300, and that there were no less costly options. This is a safety issue that should have been addressed by Toyota long ago since it was clearly a design flaw...and their recent "extended warranty" excludes way too many vehicles. complaints specifically addressing this Toyota Sienna door issue began in 2006, and now there are 74 pages and 740 reports of damaged cars and kids at risk due to inability to open the door, cables snapping and parts hitting people in the face, people attempting to address the issue by simply removing the cable and operating the door manually only to find that the door gets stuck in the open position and will not close, and owners replacing the expensive cable/motor component at an exorbitant cost only to have the problem recur. Owners of these vehicles and their children are at risk. Please address this issue promptly.

- Oak Hill, VA, USA

problem #167

Jan 212013

Sienna 6-cyl

  • 171,000 miles
Toyota issued a warranty enhancement notification for 2004-2007 model year Siennas for front door check mounting panel failures. This warranty has expired and my front door is failing due to faulty spot welds. If the door check completely fails, the door window can break injuring the driver. This problem is pervasive in these model years and Toyota needs to issue a recall.

- Eagle Point, OR, USA

problem #166

Jan 102013

Sienna 6-cyl

  • 56,107 miles
Passenger side power door cable snapped and the door wouldn't close nor open. Tried to open it manually, no luck unless you use enormous amount of power which might do damage to some other parts of the vehicle. Even if door managed to get open it won't close, which is a safety issue.

- Adelanto, CA, USA

problem #165

Dec 132011

Sienna 6-cyl

  • 55,000 miles
This has happen multiple times. Happen last year and this year. The sliding door does not close in middle of journey which forces you to drive with kids with door open until you can get the door fixed.. last year it was with left sliding door today the right sliding door got stuck in middle of my shopping trip and we had to drive with two kids 3 yrs and 6yrs with right sliding door open to home. This is common problem on internet and highway safety should consider a public recall to this sliding door problem.

- New Hyde Park, NY, USA

problem #164

Nov 152012

Sienna 6-cyl

  • 135,000 miles
Toyota Sienna's equipped with power sliding doors use a plastic coated steel wire to operate the door via a wheel and motor. This plastic deteriorates over time and the steel wire corrodes and fails leading to the inoperable ability of the door in the power mode. In power mode: The door will remain closed if attempted to be opened while the vehicle is in a motion gear. It also allows the controlled open and closure of the door with an automatic reversal if the door detects obstruction. Disengaging this power mode allows the door to be opened when in motion. It also allows the door to slam closed if vehicle is parked on an incline and could injure a person not expecting the closure or opening. Toyota has offered a "service extension", not a recall, for a part that is integral for the safe operation of the sliding doors. This extension will only cover a small percentage of vehicles in their allotted time frame. The actual failed part is not available for replacement and a whole door actuator must be purchased and installed at $1100 per door.

- Cheswick, PA, USA

problem #163

Oct 012012


  • 105,000 miles
The contact owns a 2004 Toyota Sienna. The contact stated that when opening and closing the front driver's side door, the door would exhibit a loud popping noise. The contact was concerned that the door would detach from the vehicle. The vehicle was taken to the dealer where he was advised that the welding on the door was rusted and needed to be replaced. The vehicle was not repaired. The manufacturer was contacted and offered no assistance. The failure mileage was approximately 105,000. The current mileage was approximately 111,000.

- Dunwoody, GA, USA

problem #162

Jun 152010


  • 60,000 miles
The contact owns a 2004 Toyota Sienna. The contact stated that the rear driver's side sliding door would not open. The vehicle was taken to an independent mechanic for diagnostic testing. The mechanic cut the wiring for the sliding door in order to be able to open the door. The manufacturer was contacted and sent an engineer to inspect the vehicle. The engineer advised that the sliding door would have to be replaced. After some time passed, the rear passenger's side sliding door also failed. The contact received an extended warranty notice for the replacement of the sliding door wiring however, the warranty would not cover the motor or any additional components for the door. The contact stated she had deactivated the electronic function of both sliding doors and would open them manually. Additionally, the contact stated that she later smelled a burning odor while driving with the heated seat warmer activated. The driver's seat then began smoking. The contact sustained a burn to her hand as a result. Also, the contact stated that the rear driver's side vent window completely detached from the vehicle. The vehicle was not repaired for any of the failures. The approximate failure mileage was 60,000.

- North Easton, MA, USA

problem #161

Dec 212012

Sienna 6-cyl

  • 135,000 miles
Automatic sliding side door cable snapped door slide closed on a child entering. Van was parked on a slight hill door was already open child entering door of van when cable that opens and closes door snapped and released door and door slid close slamming the child up against the door pillar between front passenger door and sliding side door.

- Mountainside, NJ, USA

problem #160

Dec 082012

Sienna 6-cyl

  • 91,089 miles
The back passenger doors both sides can not open. These happen at least 3 times already. The latches stuck.

- Saginaw, MI, USA

Read the next 20 complaints »

Not what you are looking for?