I have a 2020 RAV4 hybrid with the power lift gate.
I have had the same experience as described above and the passenger side liftgate hinge bent just as the pictures above show.
This started with the liftgate not wanting to close under power - it would start down and then just stop. At first, it could be manually closed and would latch, but over a few days it got progressively worse (presumably as the hinge bent further).
I took it to the dealer as its still under warranty. Had a very long discussion with the service manager and they just would not fix it under warranty. This ended with them saying my only option would be to take it directly to Toyota.
They gave me an estimate for fixing it and it was $14000! Lots of very detailed stuff in the estimate including replacing both hinges (even though one looked fine) and 4.1 hours of labor for painting (I guess they wanted to paint that new hinge very carefully).
I decided to give the hinge replacement a try myself and ordered the part from the dealer ($54). I figured if it turned out to be beyond me I could just take the car and hinge to our nearby body shop and let them do it. Hinge just came in today (took about 3 days).
I just finished replacing the hinge and it was surprisingly easy -- less than 2 hours going very slow.
Step by step...
- Took a bunch of closeup pics to document what the clearances were all around the hinge and tailgate.
- Pulled the 3 push pins holding the aft end of the headliner in place.
- Release the top of the trim panel around the passenger side rear window.
- The above two steps allow you to pull down the headliner enough to get access to the bolts holding the hinge to the body.
- Tied the liftgate to the tracks on my garage door to support the weight of the liftgate.
- Did not do anything to the lift actuators.
- Removed the two nuts holding hinge to body (12 mm). These are the bolts that look like rivets from the top, but are normal threaded bolts on bottom.
- Removed the two bolts holding hinge to liftgate (also 12 mm).
- Pulled the old hinge out and cleaned up the sealant around it with a chisel.
- Put the new hinge into the body holes and secured with with the old nuts - loosely tightened.
- I had cut some wood spacers to the gap sizes (vertical and horizontal) on the driver side hinge and I used these to position the passenger side of the lifetgate. I had to use a ratchet strap from back edge of liftgate to my roof rack to pull the liftgate forward so that spacing was the same as on the driver side and so that the two bolts holding the hinge to the lift gate could be inserted.
- I thought that some sort of alignment would be necessary to get the door lined up with the new hinge, but decided to just fully tighten all the bolts on the new hinge and just see how bad it was.
- Turned out it was fine with no adjustment - maybe just lucky. The door opens and closes and latches normally using the open and close buttons.
Just thought I would pass this on for others thinking about the DIY solution