Toyota Sienna Broken Welds - I'm dealing with the same problem: driver's door popping noises. Dealer said it's a broken weld, the whole door has to be replaced at the cost of close to $2000, it will take 3-4 days, no loaner provided, everything at my own costs.
I've sprained my leg, trying to get in and out.
I've dealt with Toyota corporate - no assistance. TOTAL RIP-OFF!!!
2004 Sienna is 7 years old, with only 56,000 miles.
Recommendation: Call Office of Defects Investigation, NHTSA, 1-888-327-4236
and report this safety problem. THE MORE REPORTS THEY GET, THE BETTER CHANCES THEY'LL GET TOYOTA TO ISSUE A RECALL!!!
Check out www.nhtsa.gov
We should get media attention to this problem, obviously it's a manufacturing defect, as someone said, it's a matter of WHEN the weld will break, not IF it will break.
Seems like this is a common problem. Bought Certified Used Toyota and the Platinum Extended Warranty. This covered re-welding the door. However, about a month and a half later, the welds broke again. Body shop is covering the work, but I expect the problem to happen again. Working through the Toyota Customer Experience number to see if I can get a replacement door. Since the design hasn't changed, hopefully I'll get another 5 years from a new door instead of 2 months from new welds...
I paid to have the door check fixed the first time it failed and that failed in a few weeks. My Dealer in Escanaba Michigan called me and told me of a recall and that he had ordered a door for me. Both front doors on the Sienna are covered under the recall.
But it does help to go to your dealer for oil changes and when you have a problem he will go to bat for you if he is good.
the spot weld on the drivers door let go. This is a manufactures defect. How many other welds are going to let go. Toyota will not warranty this. Of course this is not covered by the extended warranty as well. How can a weld break on a 3 yr old vehicle? This is one of the first new Siennas off the line. So far Toyota has replaced the gas tank, radiator, rr seat belt, steering joint, hydraulic power steering fitting. The old adage hold true, "do not buy a new vehicle in its 1st year of production". My dealer has fixed 5 broken spot welds. The service at my Toyota/Lexus dealership "Toyotatown" is terrible. I would never buy another vehicle from them.
- mendler,
Tillsonburg, Ontario, Canada
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Seems like this is a common problem. Bought Certified Used Toyota and the Platinum Extended Warranty. This covered re-welding the door. However, about a month and a half later, the welds broke again. Body shop is covering the work, but I expect the problem to happen again. Working through the Toyota Customer Experience number to see if I can get a replacement door. Since the design hasn't changed, hopefully I'll get another 5 years from a new door instead of 2 months from new welds...
- fpepin, Medford, OR, US