NHTSA Complaint #10398423 — 2004 TOYOTA SIENNA

PASSENGER SLIDING DOOR FAILURE. CABLE COMPROMISED DUE TO DESIGN FLAW THAT STRIPPED IT OF ITS INSULATION. DESPITE BEING GARAGED, THIS CAUSED THE CABLE TO FRAY AND THEN RUST, MAKING THE DOOR INOPERABLE. THIS INCLUDES MANUALLY, AS THE CABLE CATCHES ON A ROLLER AT THE DOOR HINGE IN THE SLIDING TRACK. ADDITIONAL FEAR IS THAT CONSEQUENT MOTOR STRAIN MAY CAUSE ADDITIONAL FAILURE/EXPENSE/FIRE. THE CABLE FAILURE CAUSES IT TO BIND ON THE HINGE ROLLER AND PREVENTS THE DOOR FROM BOTH OPENING *AND* CLOSING. IN AN ACCIDENT, YOU WILL NOT BE ABLE TO EXIT THE VEHICLE FROM THAT SIDE IF NECESSARY. DOOR DID OPEN PARTIALLY AND THEN WOULD NOT CLOSE WITHOUT GREAT EXERTION. THANKFULLY, MY WIFE WAS ABLE TO FORCE IT CLOSED BEFORE HAVING TO TAKE THE HIGHWAY WITH OUR CHILDREN INSIDE AND AN OPEN DOOR. ONCE THE PART FAILS, THE DOOR CAN NOT BE MADE OPERABLE WITHOUT MAJOR REPAIR. TOYOTA HAS TSB EL004-004 ON THIS ISSUE THAT COVERS OUR PARTICULAR VIN, BUT WILL NOT COVER THE REPAIR OUT OF WARRANTY. COST OF REPAIR IS APPROXIMATELY $2,000 AND THE FEAR IS THAT MANY, LIKE US, WILL NOT HAVE THE PART REPAIRED DUE TO THIS COST (AND ANGER OVER *ACKNOWLEDGED* DESIGN FLAW). *TR