2004 Toyota Sienna Problems

What owners report

Owners of this model year most often describe problems with the power sliding doors and rear liftgate, which are reported from low mileage onward and in some cases are linked to a dead or weak strut or a frayed cable. Steering complaints — a stiff or binding feel, sometimes after road-salt exposure — and unexpected stability-control braking on dry pavement are the next most common themes, along with cracked or sticky dashes. Many reports come in around 60,000–120,000 miles, though tire and door concerns appear much earlier.

1. 1
   Body and structure

   Power sliding door cable fails or door sticks open/closed

   • 690 complaints (33%)
   • median 83,456 mi at 6.3 yrs old (603 state mileage)
   • 24 mention a crash, fire or injury
   • owner-quoted repair $1,600 (median of 222 quotes)
   • filed 2003–2021

   Owners describe the power sliding door jamming open or refusing to latch, sometimes after a grinding or popping noise, and say the manual override does not let them close it. Several had to drive with the door open or force it shut, and some report the door cable fraying, corroding or snapping and hanging outside the vehicle. Complaints describe dealer quotes in the range of roughly $1,500–$2,000 for the door motor or cable assembly, with some vehicles beyond an extended warranty period. Reported across a wide mileage range, often between about 50,000 and 120,000 miles, and several owners mention trouble in freezing temperatures.

   What to check: Open and close both sliding doors several times in cold weather and with the power switch on and off, and listen for grinding or popping. Ask whether the door cables or motor have ever been replaced, and check the exposed cable track for rust or fraying.

   2 excerpts from owner complaints in NHTSA records

   “Toyota Sienna 04 sliding door cable is frayed and about to snap. Toyota said it will replace the cable & motor for $1500. Our 5 yr. Warranty just expired and the car only has 77000 miles. According to sites I have read, eventually the door will no longer open or may randomly open as you drive down the road. When the cable snaps, it also could hurt anyone standing near.”

   NHTSA complaint #10269420, filed 2009-05, 77,000 miles

   “2004 totally Sienna slide door froze in the open position and the manual override feature didn't work to allow me to close the door and transport my children. This appears to be occurring on a high number of Sienna's and I believe it is a clear defect. The dealer wanted $2,000 to fix the door that I believe should be a recall.”

   NHTSA complaint #10273164, filed 2009-06, 92,500 miles
2. 2
   Steering

   Stability control brakes on its own on dry roads

   Mentioned in 12 of 80 sampled complaints

   Owners report the VSC/traction warning light and beeper coming on during normal driving on dry pavement, often in a curve or slight turn, with the brakes applying and the vehicle slowing or swerving briefly. Some describe the steering wheel pulling or becoming hard to hold during the event, and a few say it happened repeatedly on highway trips. Complaints mention dealer diagnoses such as a steering angle sensor or a steering control system fault, and in some cases the problem recurred after repair. Described at a wide range of mileage and speed, from low speeds up to highway speeds, on dry roads and often while turning.

   What to check: Ask whether the steering angle sensor, wheel bearings or steering rack have been replaced, and whether any VSC or ABS warning lights have come on. A test drive on a curve at moderate speed can reveal whether the system activates unexpectedly.

   2 excerpts from owner complaints in NHTSA records

   “While driving the vsc activates, the brakes engages, the cars slows down and it make it difficult to control. It has happened to me more than 10 times. Mind you its on a dry surface and no curves. Very scary I drive it with nobody inside just in case... Thanks”

   NHTSA complaint #10649314, filed 2014-10, 14,200 miles

   “The vsc has activated multiple times on my van for no apparent reason. While driving at any speed and usually in a turn, the vsc light will flash, the warning beep will beep, and the ABS brakes will automatically be applied and the engine will quickly decelerate. I have almost been rear-ended several times because the van will suddenly decide to decelerate. I have no control over when this happens and no control of the van when it does!”

   NHTSA complaint #10454689, filed 2012-04, 98,000 miles
3. 3
   Body and structure

   Rear liftgate struts weaken and the hatch falls

   • 213 complaints (10%)
   • median 54,000 mi at 4.0 yrs old (170 state mileage)
   • 60 mention a crash, fire or injury
   • owner-quoted repair $520 (median of 21 quotes)
   • filed 2004–2025

   Owners report the power rear liftgate sagging, closing on its own or failing to hold fully open, sometimes dropping several inches when it reaches the top. Several describe the hatch closing unexpectedly and striking a person unloading the vehicle. Complaints mention dealer diagnosis of worn gas struts, and some note the vehicle was included in a campaign for the struts or that the failure returned after replacement, particularly in cool weather. Reported from roughly 37,000 miles upward, with several owners describing trouble in cold or cool conditions.

   Recall 08V244000

   What to check: Open the liftgate and see whether it holds position on its own, especially in cold weather, and check whether the struts have been replaced under the 2008 campaign. Ask for the service record showing the strut replacement.

   2 excerpts from owner complaints in NHTSA records

   “My wife parked our 2004 Toyota Sienna minivan and opened the rear liftgate from the console above the rearview mirror. She exited the vehicle and walked to the rear of the vehicle. As she turned to the open rear area the liftgate descended and struck her, causing her to fall to the ground and opening a gash in her scalp that bled profusely and required three staples to close. Our vehicle had been recalled to address this issue in 2008, but we have experienced similar intermittent and unpredictable instances since. …”

   NHTSA complaint #10367197, filed 2010-11, 109,000 miles

   “One of the two support cylinders for the rear hatch on our 2004 Toyota Sienna failed in fall 2019, so the rear hatch would not stay up. The liftgate support cylinders had previously been replaced by Toyota under recall. We purchased two new support cylinders, Toyota part #68905-ae022'support cylinder' from camelback Toyota in phoenix, az, d/b/a Toyota parts factory, by mail, shipped 11/19/19. I installed both of the new support cylinders within a couple of weeks. Note that both of the old support cylinders were replaced with new Toyota parts, not just the one which had failed. …”

   NHTSA complaint #11391004, filed 2021-02, 247,000 miles
4. 4
   Steering

   Stiff or binding steering, sometimes linked to road salt

   • 141 complaints (7%)
   • median 77,250 mi at 6.7 yrs old (118 state mileage)
   • 4 mention a crash, fire or injury
   • owner-quoted repair $696 (median of 18 quotes)
   • filed 2004–2025

   Owners describe the steering becoming heavy, catching or seizing during low-speed turns or while parking, and in some cases feeling like the power assist dropped out. Complaints mention replacement of the intermediate steering shaft or the rack and pinion, and one owner notes a bulletin covering a revised shaft for high-salt areas. A few report the power steering hose or line coming loose. Reported from about 39,000 to 190,000 miles, with several mentions of vehicles used in road-salt states.

   What to check: Turn the wheel slowly while parked and at low speed and feel for binding or a catch. Ask whether the intermediate steering shaft or rack has been replaced, and inspect the underbody for corrosion if the vehicle has been in salt-belt areas.

   2 excerpts from owner complaints in NHTSA records

   “I experienced significant difficulty (stiffness, lack of responsiveness) in the power steering of my 2004 Toyota Sienna. Subsequent examination by my dealership revealed that both the steering rack and pinion and the intermediate steering shaft needed to be replaced. The minivan has only 51,000 miles.”

   NHTSA complaint #10307762, filed 2010-02, 51,000 miles

   “Steering failed in van, no warning, became very hard and acted like steering with no to very little power steering. Required significant driver input to steer and drive vehicle. Dealer said road salt caused exposed mechanisms under car to corrode and tighten.”

   NHTSA complaint #10368224, filed 2010-11, 90,000 miles

Buying note. Check both sliding doors and the rear liftgate operation carefully, including in cold weather, and ask for records of any door cable, motor or strut work. A pre-purchase inspection that includes the steering and underbody is worthwhile, and confirm which open recalls apply to the vehicle by VIN.

Summary written with AI from a sample of 80 NHTSA complaints for this model year (picked at random, with complaints that state a mileage and recent ones taken first), then checked automatically against the source records. Where a problem shows a complaint count, every complaint for this model year was matched with fixed keyword rules (written with AI and tested against the sample), and the mileage, age and repair figures are calculated from those complaints; owners' figures are as stated, not verified. Other counts refer to the sample. The excerpts come from NHTSA's public complaint records and are unverified; capitalisation is normalised, NHTSA staff notes are removed, and shortened text ends with “…”. Something wrong? Request a correction.