Rear powered door doesn't close

I recently had and issue with the auto-lift hatch on my Limited. There’s a sensor in it to detect whether or not something is in the way while it’s closing. Page 125 of the 2023 manual.








One day (without any previous issues) it decided not to close when we hit the button, it just did a double beep and wouldn’t budge. We tried everything - turning the car on/off, using the button on the door, on the remote and the one on the dash. The only way to get it shut was to manually shut it - which was no easy task since we were forcing the gears to work manually.

I carefully washed the entire area indicated in the diagram to make sure it was dirt or dust causing the issue. I inspected the entire door several times looking for any breaks or cuts but didn’t find anything. It randomly sort of worked one day - while I was manually closing it, the auto system took over and closed it for me. I opened it with the button on the door, then closed it and it worked fine. Thought it was fixed, but the next day it was back to the same behavior.

The dealership inspected it and said it was the sensor, they’d have to order the part. It took 2 weeks to get the part in and I turned it back in for repair and got a loaner Rav4.

Once they got the sensor installed, they got an error that one of the computers was bad, which took another 2 weeks to get (he mentioned that the car has at least 21 separate computers in it!). After the computer was installed there was an error that the latch needed to be replaced. In all they had the car for 26 days.

The rep told me that the techs hadn’t seen this issue before and it wasn’t logged in the Toyo system. I could only find one reference to this issue with the Gen5 on the internet before I took it in, and that was on Reddit without much explanation just that the dealership fixed it. He said that they’d logged it with Toyo, who watches issues like this to see how widespread they are and whether or not a recall is in order. Now that they know what parts are involved, the next time someone brings in a vehicle with this issue they’ll order all 3 parts up front in anticipation of replacing them all.

Just thought I’d give everyone a heads up in case someone else with an automatic lift gate has this issue. Here are the notes and part numbers on the work order. (their notes indicate a different order of events from what the service rep told me - I’m just reporting what I was told).

“Code B225101 back door closer switch general electrical failure”
84280-47010 Sensor Assy, Power B $498.88

“Replaced back door latch/motor assembly. Switch is part of latch”
69350-0E200 115387 Lock Assy, Back Door $458.65

“After replacement of those 2 parts door opens but wont close, defective left hand jam sensor”
89222-47010 Computer, Multiplex $566.86

Labor = 1.34h
Rental cost b/c of part back order = $882

As a side note - I washed the car before I took it and the day after I got it back. I found 3 spots that were damaged in the trunk area where the paint had been knocked off down to the body. I’m working with them to get it repaired - I have complete faith that they’ll make it right so I’m not upset, sh*t happens when you’re repairing a vehicle. I did ask him about 2 weeks in if I could have it back while they waited on parts because I was worried about the batteries while it sat there for so long not being driven. He said “the vehicle is driveable but apart at the moment. Hybrid battery will be fine, if we would have any problem with the battery it would be the auxiliary battery.” So far I've had no issue with the 12v. I wonder where the car was parked during this time - and if something was laid on it that would cause such deep damage. This is the edge of the back panel where the hatch meets the body (the door is open in this pic). More than a surface scratch, that’s down to the body. There are 2 other smaller spots, one on each side where the rear fin is - odd that its in the same place on both sides…..

 

Thankfully under warranty and not out of my pocket...this time. Might be an expensive issue a few years down the road for other people unless I'm just an anomaly.