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Discussion Starter · #1 ·
The big question everyone has on their minds, was the production changed on the late 2022-2023 RAVs in regards to the roof rails.

If anyone is willing to take the roof rails off to see what's underneath, that would indeed answer if Toyota caught on what the permanent fix would be.
 

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I have a 2023, crossbars and moonroof, no leaking (yet). They also included a hardware kit with covers and screws in case I wanted to remove my crossbars. My impression is that this is the 4th-year model of the Gen5 RAV4. They鈥檝e worked out all of the kinks by now through trial and error. The only downside to buying a 2023, is that you鈥檒l miss out on the 2024. At least you aren鈥檛 buying a Kia or a Hyundai. Go nuts.
 

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2021 Rav 4 XLE gas engine
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. My impression is that this is the 4th-year model of the Gen5 RAV4. They鈥檝e worked out all of the kinks by now through trial and error.
As of this date NO ONE has ever removed the roof rails on a 2022 or a 2023 and taken and posted photos of what is underneath either here or on ToyotaNation or Reddit rav4 club. It is sheer speculation and wishful thinking to assume "all the kinks " have been worked out by now. Even the "new" orange seals used in late 2021s were and are questionable as to their durability and longevity.
 

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In TIS it doesn't look any different on a 2023 or a 2019 for XLE and up. Parts catalog also looks to be the same part numbers (using the newer style orange foam clips) even if you select a 2019, so the new parts appear to be a supersession.

LE now has a rubber strip there instead of rails, and under that strip there are no holes drilled into the sheet metal at all.

No one (to my knowledge) who has the newer style clips that began being installed in production mid to end of 2021 have had leaks yet, at least as far as this forum goes.

Mine were fixed under warranty and also have not leaked again .......... Yet...... :|
 

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I have a 2022 SE. I took my rails off to install a Prinsu. Although I didn't take any pictures before installing the Prinsu, you can still see the channel. I can send a picture if you want, but can summarize what I saw. Each side only has 5 holes now, that the factory roof rails bolt through. There are no extra holes.
 

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2021 Rav 4 XLE gas engine
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I have a 2022 SE. I took my rails off to install a Prinsu. Although I didn't take any pictures before installing the Prinsu, you can still see the channel. I can send a picture if you want, but can summarize what I saw. Each side only has 5 holes now, that the factory roof rails bolt through. There are no extra holes.
Please DO post a photo HERE!!! I believe the SE has what we call "low mount" or "flush mount" roof rails (whereas the TRD has different high rails.) On earlier model years there were two bolt holes on each side for 10mm bolts to hold on the rails and these bolt holes were drilled and threaded into the metal brackets which themselves were bolted to the roof. Between the metal brackets and in front of the front bracket were several holes drilled through the roof for the plastic clips. I really do not understand what you mean by saying your 2022 on "each side has only 5 holes now." It sounds the same as the 2019 through 2021 RAVs. A photo would sure clear this up and with your Prinsu you can easily take a photo of whatever you used to seal the 5 holes.
 

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With the metal brackets for the 10mm bolts removed there are 9 holes on each side. So if there's only 5 holes total then they removed 4 of the holes?...
If you watch from 20 minutes onward you can see all the holes. They used drills only to widen some of the factory holes.


This video shows removal of the metal brackets at 4 minutes.

 

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Discussion Starter · #9 ·
For everyone following, I found a contact at the Woodstock plant and he noted the following: If the bolts are not shot properly, they will definitely leak. However this instance is rare.

Then I asked if the new models have updated processes as there's rumors holes aren't being drilled for clips. He then said he will speak to the group leader on that side of the plant to get an idea of what's changed IF anything has changed.
 

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Discussion Starter · #10 ·
In TIS it doesn't look any different on a 2023 or a 2019 for XLE and up. Parts catalog also looks to be the same part numbers (using the newer style orange foam clips) even if you select a 2019, so the new parts appear to be a supersession.

LE now has a rubber strip there instead of rails, and under that strip there are no holes drilled into the sheet metal at all.

No one (to my knowledge) who has the newer style clips that began being installed in production mid to end of 2021 have had leaks yet, at least as far as this forum goes.

Mine were fixed under warranty and also have not leaked again .......... Yet...... :|
In TIS does it show the clip for the 2023?
 

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Discussion Starter · #12 ·
Guess we'll have to wait until someone finds a totaled one in a junk yard.
Atm every pic/vid of a third party rack install is of a '21 or earlier model
Yeah we just changed our XLE to a LE order. We saved $3700 plus taxes and don't have to worry about future issues. The power seats, auto air, sunroof and power tailgate are not worth that price tag to us. The factory remote start feature is nice, but didn't justify the upgrade price tag IF we we're going to have potential leak issues. I can get a aftermarket professional remote start for $500 that's a bit more reliable that the Toyota app.
 

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In TIS does it show the clip for the 2023?
It did, many of the diagrams for the 2023 still show the applicability start date as 2019 depending on the system, meaning the procedure is unchanged since that date.

Some now have a start date of 2023, like the diagrams related to the infotainment and camera system for example.
 

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Discussion Starter · #14 ·
It did, many of the diagrams for the 2023 still show the applicability start date as 2019 depending on the system, meaning the procedure is unchanged since that date.

Some now have a start date of 2023, like the diagrams related to the infotainment and camera system for example.
Interesting. I wonder what my contact is going to say. He's off this week and back to the plant on Monday and is also intrigued about what's changed. I saw that the clip that had the issue was used on other SUV's as well. So I wonder if other Toyota's are having the same issue.
 

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Interesting. I wonder what my contact is going to say. He's off this week and back to the plant on Monday and is also intrigued about what's changed. I saw that the clip that had the issue was used on other SUV's as well. So I wonder if other Toyota's are having the same issue.
They are correct, it also affected the early Corolla Cross models (maybe others too?).
 

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Discussion Starter · #16 ·
They are correct, it also affected the early Corolla Cross models (maybe others too?).
I think on ToyotaPartsDirect it noted that the clip was used on Highlanders as well.

I know it's a long shot, but people need to gather and submit complaints to NHTSA and others to push for a recall. The corrections members have found would be simple for Toyota to put in. But with the hundreds of thousands sold per year, a logistics nightmare to get them all in for a fix.
 

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I think on ToyotaPartsDirect it noted that the clip was used on Highlanders as well.

I know it's a long shot, but people need to gather and submit complaints to NHTSA and others to push for a recall. The corrections members have found would be simple for Toyota to put in. But with the hundreds of thousands sold per year, a logistics nightmare to get them all in for a fix.
Even the dealership who fixed mine under warranty (Mine wasn't even the first one they fixed) was beyond belief as to why Toyota Corporate had not issued some kind of TSB or recall due to the airbags and other electronics that can be affected.

I have a coworker who has an XLE who's clips failed catastrophically during an automatic carwash, we are talking water just flowing rapidly into the cabin. They took it to the dealership and they denied warranty claim due to them being a few months outside the 3/36. They escalated to Toyota Corporate and they also denied warranty.

Dealership quoted in the ballpark of 3k to fix the issue, and said they should probably just file a claim with their insurance company to cover it.

Pretty disgusting when you see the Toyota badge attached to the vehicle, which is a brand known for quality and standing behind their products.

There are a lot of average janes and joes that drive these cars and never visit a car forum like this and probably never pay attention enough to even notice water stains on the headliner. They could drive around for years and years, just oblivious that there is rust and corrosion above the headliner. Maybe their airbag system never throws a DTC, but the moment they get T-boned and the airbags don't deploy ... It kind of makes you wonder what Toyota will say then?
 

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Discussion Starter · #18 ·
Even the dealership who fixed mine under warranty (Mine wasn't even the first one they fixed) was beyond belief as to why Toyota Corporate had not issued some kind of TSB or recall due to the airbags and other electronics that can be affected.

I have a coworker who has an XLE who's clips failed catastrophically during an automatic carwash, we are talking water just flowing rapidly into the cabin. They took it to the dealership and they denied warranty claim due to them being a few months outside the 3/36. They escalated to Toyota Corporate and they also denied warranty.

Dealership quoted in the ballpark of 3k to fix the issue, and said they should probably just file a claim with their insurance company to cover it.

Pretty disgusting when you see the Toyota badge attached to the vehicle, which is a brand known for quality and standing behind their products.

There are a lot of average janes and joes that drive these cars and never visit a car forum like this and probably never pay attention enough to even notice water stains on the headliner. They could drive around for years and years, just oblivious that there is rust and corrosion above the headliner. Maybe their airbag system never throws a DTC, but the moment they get T-boned and the airbags don't deploy ... It kind of makes you wonder what Toyota will say then?
This forum is the only reason why I went for a LE. I generally don't research negative things but thankfully I did this time. The perks for going XLE or even limited are great, but the leaks and how tech gets outdated yearly now didn't make it worth while for me.

I'm sure a recall will come. It's horrible to say, but someone will get into a wreck and the airbag won't deploy because of the water damage and then things will start moving. Companies nowadays generally move to make things right once someone gets hurt.
 

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The big question everyone has on their minds, was the production changed on the late 2022-2023 RAVs in regards to the roof rails.

If anyone is willing to take the roof rails off to see what's underneath, that would indeed answer if Toyota caught on what the permanent fix would be.
best to contact a rebuilder of toyotas or the local toyota dealers body shop.
they should be able to help you.
 

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2019 XLE AWD
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Even the dealership who fixed mine under warranty (Mine wasn't even the first one they fixed) was beyond belief as to why Toyota Corporate had not issued some kind of TSB or recall due to the airbags and other electronics that can be affected.

I have a coworker who has an XLE who's clips failed catastrophically during an automatic carwash, we are talking water just flowing rapidly into the cabin. They took it to the dealership and they denied warranty claim due to them being a few months outside the 3/36. They escalated to Toyota Corporate and they also denied warranty.

Dealership quoted in the ballpark of 3k to fix the issue, and said they should probably just file a claim with their insurance company to cover it.

Pretty disgusting when you see the Toyota badge attached to the vehicle, which is a brand known for quality and standing behind their products.

There are a lot of average janes and joes that drive these cars and never visit a car forum like this and probably never pay attention enough to even notice water stains on the headliner. They could drive around for years and years, just oblivious that there is rust and corrosion above the headliner. Maybe their airbag system never throws a DTC, but the moment they get T-boned and the airbags don't deploy ... It kind of makes you wonder what Toyota will say then?
That's terrible...This is why IMO it's best to forget about the warranty and just plug up the holes if you have the low profile rails, it takes only 1 hour. When it's fixed under warranty they're not going to take extra steps with silicone, they'll just use the new clips with the orange gaskets which may or may not work in the long term. I have a 2022 Highlander XLE which uses similar rails as the RAV but I don't want to remove them if they're stuck on using adhesive.
 
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