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Toyota Sienna Power Seat problem
Some research indicates that this is becoming a frequent issue with the 2006 & 2007 models and the seat tracks were redesigned in 2008.
Toyota has a TSB0183-09 that has information about how to 'fix' the problem by replacing the seat tracks.
In my case, we have used these power seats very infrequently over the almost 4 years we have had this van.
The dealer wanted $1300 to fix the seats and their process is to send the van to a local auto upholstery shop to have the seat tracks replaced.
I wasn't happy with this and the dealer made a call to the Toyota zone rep who said that they would not help with the fix.
I called Toyota Care (1-800-331-4331) asking them to help with the fix, explaining that they have a defect, have published information (TSB) about the defect and how to fix it, and redesigned the part in a later model so they should stand behind their product and at least pay part of the repair costs. They said NO. That the van is out of warranty and their is nothing they will do. I asked if there was some kind of appeal process and was told NO - that was their final answer.
So, I decided to call the local auto upholstery shop that the van would be sent to and talk to them about it. I was told they have fixed 'a lot' of these seats for the Toyota dealer. He said that their labor charge is $150/seat. He also mentioned that he had recently installed a new seat track and and found that the new track had the exact same problem. He said he was able to make an adjustment and get it working. He suggested that I bring him the van and let him take a look and that he might be able to get it working again without replacing the seat tracks.
I took the van to the Upholstery shop and he found that there were 2 springs broken (one in each seat). He replaced the springs and adjusted the seats and everything works correctly now. Total cost: $200. Sure beats $1300.
I wanted to share this experience with everyone. I would suggest finding out from the dealer who they would send the van out to and then contact that place directly to see about having them adjust or repair your seats.