Roof Rail Defect Can Allow Water to Short Toyota RAV4 Electrical System, Class Action Says

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A proposed class action alleges the roof rails of 2019-2021 Toyota RAV4 SUVs are affixed to the vehicles in a manner that can allow water to leak through the roof and eventually short critical electrical components. 

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The 47-page case says that to affix the roof rails to a RAV4, Toyota drills holes in a vehicle’s roof and mounts the rails with white plastic stakes and thin rubber gaskets. The suit claims these rubber gaskets are made with material that “rapidly degrades”—namely from exposure to rain, snow, ice and car washes—and can allow water to enter the vehicle and come into contact with its electrical system. 

More specifically, water can leak through a RAV4 roof into the vehicle’s pillars, which house its air bags, and down into the car’s dashboard area, which houses electrical components critical for the vehicle’s operation, the lawsuit says. Further, water intrusion can produce mold and rust a vehicle’s frame, the case adds.

According to the complaint, Toyota knew of the roof rail defect as early as 2019 yet waited until September 2021 to alter the design of the problematic rubber gaskets to address the problem. The automaker now uses “a far thicker material” that does not degrade from exposure to the elements, the case states.

The lawsuit alleges, however, that Toyota concealed this small but significant design change from drivers. 

“Toyota did not issue a recall or even a Technical Service Bulletin [] to alert its dealers to change the plastic stakes to remediate the defect,” the suit alleges. “Instead, Toyota has allowed these leaks to continue, which create a dangerous safety hazard when the vehicle’s electrical components malfunction without warning or when water damages the vehicle’s air bags, causing them to malfunction.” 

The plaintiffs, two consumers from North Carolina, say that their vehicle became “inoperable and can no longer be driven” due to water leakage stemming from the RAV4 roof rail defect. Per the complaint, the car was initially brought to a Toyota dealer in October 2022 to address electrical issues and remains there “in a state of total disrepair.” 

“Despite its knowledge of this defect, Toyota has denied any warranty coverage to Plaintiffs,” the suit claims.

The lawsuit looks to cover all persons who bought and/or leased a 2019-2021 Toyota RAV4 in the United States.

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