Check out your door sensor as they're a known problem and generally easy to fix. That should take care of most of your issues but the door leak. I'm guessing that's just a door seal.

 

It's 10 yrs old, what do you expect them to do? Is it still under some warranty?

Roof or suicide door leak? The Interior/Exterior section has STICKY (white thumb tacked) threads on the subjects.

My 1st thought, same as Speedrye's, door jamb switch.

Amazon.com: for Toyota FJ Cruiser 2007 08 09 10 2011 Door Jamb Switch | Plastic | Black | Square | Blade Type | Replacement for 8423160070 : Automotive

 

It's 10 yrs old, what do you expect them to do? Is it still under some warranty?

Roof or suicide door leak? The Interior/Exterior section has STICKY (white thumb tacked) threads on the subjects.

My 1st thought, same as Speedrye's, door jamb switch.

Amazon.com: for Toyota FJ Cruiser 2007 08 09 10 2011 Door Jamb Switch | Plastic | Black | Square | Blade Type | Replacement for 8423160070 : Automotive

I was told that there is a warranty on 'safety items' like seat belts and such that extends past the manufacturers warranty. I had a puppy that chewed 'everything', and she almost completely chewed through the passenger seat belt (and window cranks, steering wheel, etc) and was told that if it failed, I could get it replaced, but the dog trying to eat it meant it was on me, and I needed fresh undies at the price at the time. Did that change, or is it still a thing? Is there/was there a different warranty on things like seat belts?

On the wetness, I'd be wondering if there is a rubber plug missing. (Weird possibly unrelated story: I had an amazing Audi A4 that someone in Germany routed the A/C drain into the back foot well. I didn't discover it until I drove across country in a hideous wicked rain storm all the first day, with the A/C running to keep the windows from fogging. The next morning, I discovered I had over an inch of standing water in that back area. I had to borrow a couple shower towels to try to mop/drain it. (Audi fixed the problem, but refused to replace the carpet. It sat all night sopping wet, and I was surprised it didn't develop mold to high heaven))

 

Mine had a portion of the seat belt wet, fixed by a leak test at shop for 60 bucks a couple years back.

 

You haven't provided much specific information on the 'wet seat belt' issue that would help diagnose what's going on.

A few questions:
1. Are you the original owner of the vehicle, and are familiar with every aspect of the vehicle's history?
2. Which seat belt is getting wet?
3. Which portion of the seat belt is getting wet?
4. Do you have a roof rack installed, and if so, is it the original OEM Toyota roof rack, or an aftermarket rack?
5. If no rack is currently installed, or was ever installed, have you checked the tightness of the 12 bolts and the sealing washers that plug the mounting holes for the roof rack?
6. Has the front windshield ever been replaced?

And I've got to say that you've got "Urgent safety and reliability concerns" sounds slightly hyperbolic ... these issues are probably annoying, and maybe even reaching 5-6 on a 10-point annoyance scale, but do these annoyances really reach the level of an "URGENT SAFETY CONCERN"??

Urgent Safety Concerns triggers mental pictures of dismemberment, absolute and total loss of braking function, massive gasoline leak onto a hot exhaust manifold, etc.

 

It's 10 yrs old, what do you expect them to do? Is it still under some warranty?

Roof or suicide door leak? The Interior/Exterior section has STICKY (white thumb tacked) threads on the subjects.

My 1st thought, same as Speedrye's, door jamb switch.

Amazon.com: for Toyota FJ Cruiser 2007 08 09 10 2011 Door Jamb Switch | Plastic | Black | Square | Blade Type | Replacement for 8423160070 : Automotive

The roof Leak seems to be a thing Hannibal from research. I complained about it years ago to the dealer with no luck. I would imagine if you had a fault with a product you built and it wasnt addressed

You haven't provided much specific information on the 'wet seat belt' issue that would help diagnose what's going on.

A few questions:
1. Are you the original owner of the vehicle, and are familiar with every aspect of the vehicle's history? Yes I am the original owner
2. Which seat belt is getting wet? it is the front drivers side
3. Which portion of the seat belt is getting wet? When my wife or I go to put the seat belt on it is wet on our shoulder and chest. This is after a big bit of rain and has happened for maybe the last 8 years but not all the time, just intense rain.
4. Do you have a roof rack installed, and if so, is it the original OEM Toyota roof rack, or an aftermarket rack? I do have a original OEM roof rack installed at purchase.
5. If no rack is currently installed, or was ever installed, have you checked the tightness of the 12 bolts and the sealing washers that plug the mounting holes for the roof rack?
6. Has the front windshield ever been replaced? No it has never been replaced.

I appreciate your response

 

The roof Leak seems to be a thing Hannibal from research. I complained about it years ago to the dealer with no luck. I would imagine if you had a fault with a product you built and it wasnt addressed

Ok, so it's been going on for 8 years.

It might be something as simple as a new roof rack Hardware Kit found here.

Roof Rack Parts List | Toyota FJ Cruiser Forum (fjcruiserforums.com)

How are the belt mouldings? There are holes in the doors for the clips to go into and the clips have seals.

Replacing the door moulding/window weather stripping | Page 3 | Toyota FJ Cruiser Forum (fjcruiserforums.com)

 

As the roof rack was a dealer-installed accessory (rather than port-installed), for the wet seat belt problem the first thing I'd look at would be the roof rack mounting bolts and their seals. This is not a complex task, although all the bolts would have to be loosened to allow the rack mounting feet to be lifted slightly off the roof to allow the seals to be inspected or replaced.

Any bolts that are difficult to loosen because of rusted threads would automatically confirm that there was water leakage at the rusted bolts.

 

As a dealer-installed accessory (rather than port-installed), for the wet seat belt problem absolutely the first place I'd look at would be the roof rack mounting bolts and their seals. This is not a complex task, although all the bolts would have to be loosened to allow the rack mounting feet to be lifted slightly off the roof to allow the seals to be inspected or replaced.

Any bolts that are difficult to loosen because of rusted threads would automatically confirm that there was water leakage at the rusted bolts.

Thank you for your help. It is greatly appreciated-I will give that a go and change out the door sensors.

 

Set the dome light to door then open a door if dome light don't turn on change that door switch, check each door, more than likely its the same door as the wet seat belt. check the weather strip on that door usually the window belt strip.

 

Roof rack bolt leaks can happen. A pain to fix, but doable. The door switch is easy. The worst case is a roof body seam leak caused by insufficient sealer applied at the factory, link below. Neither of these issues has Toyota ever been held responsible for, especially since the vehicle is older and now out of production. Toyota won't even take responsibility for poor frame paint and doing remediation, like they did with the Tundra, so why would they bother with the FJ?

https://www.fjcruiserforums.com/threads/warning-fjc-owners-inner-structure-rust.474026/post-6642986

 

Do read up on replacing the roof rack, in regard to loosening bolts. If you dont gently crack the pair of them loose "together"...then you can snap off the retainer-nuts inside the roof and youll be dropping the headliner.

Odd it would suddenly spring a leak, but I suppose over time it can happen. But any changing of the rack or windshield, and its commonplace for this to occur.

Also check all the door seals...could be a little tired after ten years.

 

All of these are realistic and great answers, btw. All of which are fairly low cost alternative. It’s a bummer that you are getting the run around at your dealership. Sometimes you can find a local Import or Toyota specialty shop that can help or has run into these issues before. To be clear, a shop will take the same methodical approach to solving your FJ issues. The forum may have saved you a ton of time and $ not to mention the peace of mind regarding your seatbelt concerns. If your belt assembly is rusted, I’d order a new one (or find a good condition used one) and replace that when you fix your door/ roof leak.

 

So given the excellent answers already here, my question revolves around the dealer.

When you say “reached out to …”, exactly what does that mean? Did you drive up to the Toyota dealer service window and face to face on the issues? Or did you write a letter to the CEO at Toyota Japan? Your post title of “urgent etc etc“ make me question your contact methodology for effectiveness. Different people receive different responses based on different approaches - especially when the dealer clearly has no direct responsibility for this issue.

Did you give your FJ over to Toyota service and ask them to fix the issue and call you when they are done with the bill?

 

Most if not all of what you are concerned about are programmable features. Read your manual too stop or change times. I know I turned off the auto lock feature when I purchased my 2014.

 

Before the FJ, I had a Prius, and I was amazed at the number of things that could be tweaked through their programming. I pretty much left it alone, except for one thing that escapes me now. I think it was a warning bell for something. 'DIVE DIVE DIVE!!'

Locking the keys in the FJ? I don't think I can do that to mine, not that I've tried much, but I believe that it refused to when I forgot that the spare fob was in it. I'll have to try that I guess. That Prius wouldn't lock if a fob was inside. Looking at the new cars with their fancy key-less starting, they don't seem to have any key lock holes anywhere. So how can someone pick themselves into their own car? The wife's 4-Runner came with a 'key' hidden in the fob, but being that it's her car, I haven't investigated what that 'key' might fit beside lifting the pull tab on a can of soda. I don't imagine it fits much, glove box? Don't know. I'm not allowed in it much.