NHTSA Complaint #11718624 — 2020 TOYOTA RAV4

I am submitting this complaint regarding a structural failure of the rear liftgate hinges on my 2020 Toyota RAV4 XLE. The liftgate began opening and closing crooked, and I noticed the door was no longer aligned evenly. After inspection by Toyota dealership, I was informed that the metal hinges attached to the liftgate and body are cracked and must be replaced. This failure is not the result of an accident, misuse, or impact. I have never been in a collision involving the rear of the vehicle. I was told this damage is considered “wear and tear,” so my insurance company declined coverage. The Toyota dealership also declined to cover the repair, stating it is not covered under warranty so I will have to pay out of pocket. However, after researching this issue, I found that many other Toyota RAV4 owners have reported the same hinge cracking and liftgate misalignment problem. This appears to be a widespread manufacturing or design defect rather than normal wear. This is a serious safety concern. If the hinges continue to crack, the liftgate could fail completely and fall, potentially causing injury. The misalignment also prevents the liftgate from opening and closing properly, which affects vehicle safety and usability. I am requesting that NHTSA investigate this issue and consider whether a safety recall or technical service bulletin is necessary to protect drivers and passengers. Thank you for your time and consideration.