IsItAGoodCar
Reliability Guide

Common Problems with the
2004 Toyota RAV4 Mk2 (XA20)

We've identified 2 known issues that can affect the 2004 Toyota RAV4 Mk2 (XA20). 1 of these are serious faults that could be expensive to repair.

2
Known Issues
1
Serious
0
Moderate
1
Minor

All Known Issues

Front Suspension Coil Spring Salt Corrosion Fracture

SeriousSuspension & Chassis

The front MacPherson suspension coil springs are prone to corrosion fatigue and sudden cracking, accelerated by winter road grit and moisture accumulating in the lower spring perches. If the lower coil fractures, the broken spring end can foul the inner wing or puncture the front tyre sidewall at speed, posing a severe safety danger. Toyota issued UK safety recall campaign R/2004/048 to inspect and replace affected springs.

Est. Repair Cost: £180–£350
Warning Signs:

Loud metallic twang or twanging ping sound when manoeuvring the steering at low speeds, One front corner of the vehicle sits visibly lower than the opposite side, Creaking or scraping noises from front wheel wells when driving over speed humps, Vehicle pulls to one side under straight-line braking

What to Inspect:
  • Visually inspect the front springs for flaking powder coating, heavy rust pitting, or missing coils
  • Verify on the GOV.UK vehicle recall checker that front suspension recall campaign R/2004/048 was executed
  • Listen for metallic clunking while an assistant turns the steering wheel lock-to-lock
Verified by IsItAGoodCar Research TeamUpdated
Official Recalls & Reference Documents:

Rear Side-Hinged Tailgate Hinge Sag and Latch Misalignment

MinorBodywork & Rust

The side-hinged rear tailgate carries the full weight of the external spare wheel and carrier assembly. Over years of use on uneven UK roads, the upper and lower hinge pins wear, causing the heavy tailgate door to sag. The misaligned door scrapes against the rear bumper threshold, rattles over potholes, damages the door latch mechanism, and allows rainwater to bypass the weather seal into the boot well.

Est. Repair Cost: £120–£280
Warning Signs:

Rear door catches or scrapes noticeably on the plastic bumper threshold when closing, Persistent rattling and vibration from the boot area when driving over uneven tarmac, Door handle requires excessive force to release the tailgate latch mechanism, Damp boot carpet or standing water accumulated in the rear underfloor tool tray

What to Inspect:
  • Open the rear tailgate halfway and lift upwards firmly to feel for play in the hinge pins
  • Inspect the top surface of the rear bumper for paint abrasion and plastic gouges from door contact
  • Lift the boot floor carpet and inspect the steel floorpan for rust staining or water pooling
Verified by IsItAGoodCar Research TeamUpdated

Buying Tips for 2004 Toyota RAV4 Mk2 (XA20)

  • On 2.0 petrol automatic models, test shift quality rigorously from 1st to 2nd gear to check for violent jerking caused by ECU circuit failure.
  • Lift and inspect the side-hinged rear tailgate to ensure the door hinges have not sagged under the weight of the spare wheel.
  • Inspect the front suspension coil springs for corrosion, peeling paint, or missing coils that can cause puncture hazards.
  • Engage four-wheel drive and listen for excessive whining or rumbling from the rear differential and prop-shaft centre bearing.
  • Examine the underside floorpan and sills for scrape damage and rust if the vehicle has been used off-road or on farm tracks.
20032005–2006
Check a 2004 Toyota RAV4 Mk2 (XA20) by Registration