NHTSA Complaint #10684280 — 2005 TOYOTA SIENNA

DRIVER SIDE DOOR CHECK STRAP WELD FAILING, CAUSING DOOR TO DROOP/POP AND LOOSEN FROM FRAME OF BODY. 100'S OF OTHER SIENNA OWNERS ARE REPORTING THIS PROBLEM(CHECK CARCOMPLAINTS.COM), AND AFFECTS THE DOOR INTEGRITY, THEREFORE CAUSING HUGE CONCERNS DURING A POTENTIAL ACCIDENT. THIS MAY INCREASE THE CHANCES OF DRIVER DOOR FROM REMAINING INTACT DURING A COLLISION, OR WORSE A FATALITY. I HAVE NEVER SEEN SUCH A WELD FAILURE IN ANY NEW OR OLD VEHICLES THAT I HAVE OWNED, AND SEEMS TO BE A DESIGN/ASSEMBLY ERROR. TOYOTA ISSUED A WARRANTY EXTENSION FOR 5 YEARS FROM PURCHASE BUT MOST WELDS FAIL AFTER 6 OR MORE YEARS OF OPERATION. STRUCTURAL REPAIRS OF THIS CALIBER SHOULD BE DONE BY THE FACTORY NOT AT THE LOCAL REPAIR SHOP, AND MUST MEET CRASH TEST TOLERANCES. THERE ARE OVER 100K SIENNA'S ON THE ROAD, AND THIS SHOULD BE INVESTIGATED. TOYOTA WAS NOTIFIED OF THIS CONCERN, AND COULD NOT PROVIDE SERVICE SINCE WARRANTY HAS LAPSED. IT MAKES YOU WONDER HOW STRONG THE OTHER HINGE WELDS ARE.... *TR