NHTSA Complaint #10311287 — 2006 TOYOTA SIENNA

DESCRIPTION OF PROBLEM: 2006 TOYOTA SIENNA SLIDING DOOR ON DRIVER'S SIDE WON'T CLOSE. EVENTS LEADING UP TO PROBLEM: DROVE VEHICLE ABOUT 25 MILES FROM HOME, OPENED SLIDING DOOR FOR CHILD TO EXIT VEHICLE, DOOR WOULD NOT CLOSE AFTER THAT. FRONT LATCH CAN BE SECURED WITH GREAT FORCE, HOWEVER THE REAR LATCH WILL NOT ENGAGE. DOOR REMAINS OPEN AND IS A VERY SERIOUS SAFETY RISK AS THE FRONT LATCH SECURITY/RELIABILITY IS INSUFFICIENT. SLIDING DOOR COULD OPEN WITHOUT WARNING WHILE DRIVING 70 MPH. LIGHTS IN VAN STAY ON, PRESENTING ANOTHER RISK AT NIGHT BECAUSE VISION IS INHIBITED GREATLY BY INTERIOR LIGHTING. HAD TO DRIVE HOME WITHOUT DOOR FULLY CLOSED AT NIGHT. THIS LACK OF VISIBILITY NEARLY RESULTED IN SEVERAL ACCIDENTS. PROBLEM STEMS FROM THE MECHANISM THAT GRABS THE METAL LOOP THAT IS CONNECTED TO THE REAR DOOR FRAME. THE C SHAPED LATCH IS COVERED WITH A PLASTIC COATING WHICH WHEN WORN OR DAMAGED ALLOWS MOISTURE IN AND THE METAL CLAMP SWELLS UP AND BINDS THE LATCH. NO AMOUNT OF LUBRICATION WILL HELP. TOYOTA MADE A BIG MISTAKE BY PLASTIC COATING A METAL THAT WOULD RUST AND SWELL UP THE OUTER COATING FROM THE INSIDE MAKING THE LATCH NOT FUNCTION PROPERLY. THIS IS A SERIOUS DESIGN DEFECT. THERE MAY BE OTHER DESIGN FLAWS CONTRIBUTING TO THE MALFUNCTION OF THIS CRITICAL MECHANISM. *TR