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You might try going to http://rav4world.comA lot of people posting there have the dash rattle problem. Some have had it resolved, and they can tell you about the Tech Service Bulletin Toyota put out on this problem.Also addressed there are hard ride, roof racks, and cold idle speed.
About the hard ride, check your tire pressure. It should be 29 lbs psi, but a lot of RAVs leave the dealer's over-inflated (mine were over 45 all around). It seems Toyota puts a lot of air in the tires for the boat ride over to the US to avoid flat-spotting the tires, and the dealers aren't checking this before selling the RAVs. Getting the pressure right might cure your problem. It has worked for others.
Between that site and this one, you may find your answer.Good luck with a fix.
A bit more readable than the first link posted (that font is waaaay too small for me!), plus there's a nice picture of our beloved RAV getting its rear window smashed... (ouch!!).
I just want to find out everyone's reaction after reading this article. Were you aware of this when you bought the car? I know I was... I saw those crash tests on TV and even though I knew RAV had this problem, I was willing to live with it, as long as I had the full spare when I get a flat.
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