Category Archives: Toyota

News about Toyota automobile manufacturer. News about Toyota recalls, technical service bulletins (TSB), and problems regarding Toyota vehicles.

2024-2025 Tacoma 4-Wheel Drive Reduced Braking

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A potentially serious issue has been identified in certain 2024-2025 Toyota Tacoma 4-wheel drive trucks, prompting a safety recall by the manufacturer. The problem involves dirt buildup inside the rear wheels of affected vehicles, which can cause damage to the rear brake hoses and potentially lead to brake fluid leaks.

The issue affects Toyota Tacoma trucks equipped with 16-inch brake systems and 17-inch wheels, where the brake hoses are attached to the rear brake calipers and transfer brake fluid under hydraulic pressure. The clearance between the brake hoses and wheels in these vehicles is smaller than in other combinations, making them more susceptible to damage from mud and dirt buildup.

When operating in off-road conditions, mud and dirt can accumulate on the interior of the rear wheels and come into contact with the brake hoses. Over time, this can cause wear and tear on the hoses, leading to damage and potentially resulting in a brake fluid leak. A brake fluid leak can reduce brake performance and increase stopping distances, significantly increasing the risk of a crash.

The problem was first reported by dealers in mid-July 2024, with several instances of rear brake hose leaks observed in 2024 Toyota Tacoma vehicles with the affected wheel and brake combination. Upon further inspection, dealer technicians found that the rear brake hoses were damaged and worn through, and that mud and dirt buildup on the inside of the rear wheels was causing the hoses to rub against the debris.

Toyota’s investigation into the issue revealed that the manufacturing processes used to install the brake hose were following proper routing procedures. However, a design review of the rear brake system found that the clearance between the brake hose and wheel in affected vehicles was smaller than in other combinations. Additionally, the positioning of the rear brake hose on 16-inch brakes was different and outside of the rear caliper profile.

Based on the results of its investigation, Toyota concluded that 4-wheel drive vehicles with 16-inch rear brakes and 17-inch Toyota wheels may experience rear brake hose damage due to mud and dirt buildup on the interior of the wheels. The company has decided to conduct a safety recall to address the issue. As of January 29, 2025, Toyota has received five field technical reports and twelve warranty claims related to this condition in affected vehicles.

To correct the problem, dealers will replace both rear brake hoses in affected vehicles. Interim letters notifying owners of the safety risk are expected to be mailed on March 24, 2025, with a second letter to follow once the remedy is available. Toyota’s recall numbers for this campaign are 25TB04 and 25TA04, and the NHTSA campaign number is 25V-058.

RAV 4 SUV Squeaks And Brake Problems

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The Toyota RAV4 is known as a compact SUV renowned for its dependable performance, adaptability, and impressive fuel efficiency. While it has earned a commendable reputation overall, certain model years have seen reported issues, prompting owners to navigate through a spectrum of challenges.

Some common problems experienced by RAV4 owners include:

Brake problems emerge as a recurring concern among RAV4 drivers, including issues such as premature brake pad and rotor wear, disconcerting brake noises, and unsettling brake fluid leaks. These problems not only compromise safety but also demand timely intervention from skilled mechanics to conduct thorough inspections and execute requisite repairs. The intricate interplay of brake system components necessitates meticulous attention to detail to ensure optimal functionality.

Another issue encountered by RAV4 owners revolves around squeaking noises emanating from various areas of the vehicle. These auditory disturbances could originate from suspension bushings, brake pads, or even interior trim pieces, confounding both drivers and mechanics alike in their quest for pinpointing the exact source. Addressing squeaking noises entails a systematic diagnostic approach, coupled with the technical acumen to remedy underlying causes effectively.

Transmission issues represent a notable headache for certain RAV4 owners, manifesting in the form of erratic shifting patterns, disconcerting hesitation, or ominous slipping sensations. Tackling these transmission problems often entails a multifaceted approach, including fluid replenishment, software updates, and in more severe instances, complete transmission overhauls.

Electrical problems cast a shadow of uncertainty over RAV4 ownership experiences, as drivers contend with an electrical system susceptible to a myriad of maladies. From temperamental sensors to glitchy infotainment interfaces and vexing electrical shorts.

Certain RAV4 models have encountered engine-related issues, ranging from excessive oil consumption and rough idling to outright engine stalling. These afflictions, though relatively rare, underscore the imperative of adhering to stringent maintenance protocols and promptly addressing emerging issues to safeguard the longevity and performance of the vehicle’s powerplant.

OCS Sensors May Short Circuit In Lexus And Toyota Vehicles

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Toyota Motor Engineering & Manufacturing (Toyota) has announced a significant recall affecting a range of Lexus and Toyota vehicles from the 2020 to 2022 model years. This recall, necessitated by a defect in the Occupant Classification System (OCS) sensor, underscores a critical safety issue that could potentially prevent the deployment of the front passenger airbag.

The recall spans a variety of models, including:

  • Lexus ES (2020-2021)
  • Lexus ES Hybrid (2020-2022)
  • Lexus RX and RX Hybrid (2020-2021)
  • Toyota Avalon and Avalon Hybrid (2020-2021)
  • Toyota Camry and Camry Hybrid (2020-2022)
  • Toyota Corolla, Highlander, and their Hybrid variants (2020-2021)
  • Toyota RAV4 and RAV4 Hybrid (2020-2021)
  • Toyota Sienna Hybrid (2021)

The issue originates from the Occupant Classification System sensors located in the front passenger seat. These sensors play a pivotal role in the Supplemental Restraint System (SRS), determining the deployment of the front passenger airbag based on the occupant load. A defect has been identified wherein, during production, the sensor’s Printed Circuit Board (PCB) became deformed. This deformation can cause a crack in a capacitor, leading to moisture intrusion over time and resulting in a short circuit.

The malfunctioning of these sensors poses a significant risk. In the event of a short circuit, the SRS warning lamp and the “Passenger Airbag OFF” lamp will illuminate, accompanied by a message on the Multi-Information Display (MID). The most concerning consequence is that the front passenger airbag may not deploy in certain crashes, markedly increasing the risk of injury to the occupant.

To address this issue, Toyota dealers will conduct inspections and replace the sensor where necessary. The recall is comprehensive in its scope, and owner notification letters are expected to be dispatched starting February 4, 2024.

Toyota has assigned the numbers 23TB15/23TA15 for Toyota and 23LB03/23LA03 for Lexus vehicles to this recall. Additionally, the National Highway Traffic Safety Administration (NHTSA) has registered this recall under campaign number 23V-865.

This recall by Toyota highlights the intricate nature of modern automotive safety systems and the critical importance of their proper functioning. Owners of the affected vehicles are urged to heed the recall notice and have their vehicles inspected and repaired as necessary to ensure their safety and that of their passengers.

Toyota and Lexus Airbag Problem

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AirbagToyota and Lexus have announced that they will be reaching out to owners of specific vehicle models due to a critical problem related to the electrical connection inside the steering column. This issue has the potential to disable the driver’s side airbag, leading to non-compliance with Federal Motor Vehicle Safety Standards for Occupant Crash Protection.

The problem first came to Toyota’s attention in May 2023 when they were contacted by the spiral cable assembly supplier. The supplier informed Toyota about an ongoing investigation into the manufacturing process, which revealed contamination in the washing station for specific spiral cable components. As a consequence, a poor welding condition could occur between the Flexible Flat Cable (FFC) and the bus bar, which affects connectivity to various controls on the steering wheel. Extensive testing conducted by the supplier between late-May and late-June indicated that the FFC might detach from the bus bar at the weak weld connection area.

As per the defect report, the steering column assembly in the affected vehicles contains electrical connections to the driver’s airbag module housed within a spiral cable assembly, including the FFC. In cases where the FFC is inadequately welded to the spiral cable’s bus bar, there is a risk of the FFC separating, resulting in one or more open circuits linked through the FFC. This separation specifically impacts the circuit responsible for connecting the driver’s airbag module. If connectivity is lost, the SRS warning light will activate, and the driver’s airbag may be deactivated, failing to deploy in a crash scenario that necessitates its activation. Consequently, this raises the likelihood of driver injury in the event of a crash.

 

The vehicles affected include:

2023-2024 Lexus NX Hybrid
2023-2024 Lexus NX250
2023-2024 Lexus NX350
2023 Lexus RX Hybrid
2023 Lexus RX350
2023 Lexus RX500H
2023 Toyota Corolla
2023 Toyota Corolla Cross
2023 Toyota Corolla Cross Hybrid
2023 Toyota Highlander
2023 Toyota Highlander Hybrid
2023 Toyota Tacoma

Dealers will inspect and replace the spiral cable assembly as necessary. Toyota’s number for this recall is 23TA08, Lexus’ number for this recall is 23LA02 and the NHTSA campaign number is 23V-480.

2021 Toyota C-HR Pre-Collision System Inoperative Without Warning

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In December 2020, Toyota began an investigation into certain 2021 Toyota C-HR crossover SUVs after receiving field reports from the Japanese market alleging that when using the Traffic Movement Notification feature (a Japanese market feature not available in the U.S.), the vehicle radar sensor did not detect a vehicle driving in front of it. An inoperative radar sensor also meant that other features, such as Pre-Collision System (PCS), Dynamic Radar Cruise Control (DRCC), and Lane Tracing Assist (LTA) could be affected. In these cases, dealer technicians observed that the beam axis for the radar sensor was out of specification and adjusted it during the inspection. After completing the adjustment and initializing the radar sensor, the vehicles were able to detect the preceding vehicle.

According to the defect report, certain 2021 Toyota C-HR vehicles are equipped with a millimeter-wave sensor (radar sensor) and a camera to detect objects in front of it. These sensors also support certain driver assistance features, including the Pre-Collision System (PCS).

Under certain circumstances, the initialization of the radar sensor may not have been completed correctly, resulting in the PCS not being able to detect an object in front of it. As a result, the vehicle will not provide warnings or braking assist, and would not display a message or indicator to the driver that PCS is not functional. An inoperative PCS, without a PCS malfunction indicator to the driver, may increase the risk of a crash in certain driving situations.

As of January 2022, Toyota has not received any U.S. field reports or warranty claims related to this condition. Based on their investigation results, however, Toyota decided to conduct a voluntary safety recall campaign. Owners of the subject vehicles will be asked to take their vehicles to their Toyota dealer to have the radar sensor inspected and properly initialize if necessary. Toyota’s number for this recall is 22TA02 and the NHTSA campaign number is 22V-107.

2021-2022 Toyota Sequoia and 2021 Toyota Tundra Power Steering Leak

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Toyota will be contacting the owners of certain 2021-2022 Sequoia and 2021 Tundra trucks because of a problem affecting the power steering gear assembly. Owner notification letters are expected to be sent out on January 22, 2022.

In late September 2021, Toyota observed an increase in field reports and warranty claims affecting the power steering in certain 2021-2022 Sequoia and 2021 Tundra trucks. A high percentage of these vehicles experienced power steering fluid leaks, all from the area of the power steering gear assembly. Manufacturing records showed that these reports mainly involved vehicles produced during the months of August and September 2021. Toyota began recovering additional parts involved in these reports and sent them to the supplier for inspection.

These inspections found that the circlip holding the oil seal and end stopper in position at the end of the power steering rack housing was disengaged from the groove machined in the rack housing and that the oil seal and the end stopper were moved from the correct position. Further investigation of the returned parts revealed that the groove where the circlip is installed was improperly machined leading to an incorrect groove shape.

Based on these findings, the supplier investigated their production process and identified that one of the four pieces of equipment used to machine the groove in the rack housing was not creating a groove of the correct shape. The tool was inspected, it was found that certain teeth on the cutting tool, which creates the groove in the rack housing, were damaged. Based on these results Toyota has decided to conduct a safety recall campaign.

Owners of the affected vehicles will be notified to return to their Toyota dealer to have the power steering gear assembly inspected and replaced if necessary. Toyota’s numbers for this recall are 21TB10 and 21TA10, and the NHTSA campaign number is 21V-920.

Toyota Tundra Headlight Electrical Connector Could Overheat

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Toyota will be asking owners of certain 2018-2021 Tundra trucks, to return to their dealership for a problem affecting the electrical circuits controlling the headlights in their vehicle.

The problem began in early April 2020 when Toyota received a field report alleging the headlamp connector on a subject vehicle overheated and caught fire. Since then, there have been 18 Toyota Field Technical Reports (12 alleging an inoperative headlamp and/or damage to the headlamp connector (e.g., connectors melting), but no apparent flame, and 6 alleging a flame at the headlamp assembly). There has also been 47 warranty claims (44 alleging an inoperative headlamp and/or damage to the headlamp connector (e.g., connectors melting), but no apparent flame, and 3 alleging a flame at the headlamp assembly).

According to the defect report, the subject vehicles are equipped with halogen headlamp electrical circuits that were designed incorrectly to allow the circuits for both the high and low beam bulb filaments to be energized simultaneously when the high beams are switched on. If the high beams are subjected to repeated extended use (e.g., continuously switched “on” in a commercial setting when the vehicle is idling or driving at low speed for extended periods of time and not allowing air flow to cool the headlamp connector), excess heat could lead to degradation of the bulb insulation and eventually the bulb connector. This can cause an open headlamp circuit, leading to an inoperative headlamp that can be noticed by the driver and repaired. However, if an open circuit does not occur, there is a possibility that the connector could continue to overheat, resulting in an increased risk of a fire.

Owners receiving notices will be asked to return to their dealers to have the engine wire harness assembly and headlight assembly inspected and replaced as necessary. Toyota’s numbers for this recall are 21TB06 and 21TA06 and the NHTSA campaign number is 21V-688.

2019-2020 Toyota Yaris Fuel Pump Failure And Engine Stall

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Toyota will be asking the owners of certain 2019-2020 Toyota Yaris vehicles to return to their dealerships for a problem that could lead to fuel pump failure and an engine stall.

Last year Mazda, which is responsible for the vehicle’s design and manufacturing, started an investigation into Mazda and Toyota vehicles experiencing fuel pump failures. Based on the recovered parts and other investigations, Mazda reported that the fuel pumps in the subject vehicles were affected by exposure to high environmental temperatures.

According to the defect report, these vehicles are manufactured with low pressure fuel pumps with low density impellers. These impellers were exposed to production solvent drying for longer periods of time which make them more susceptible to fuel absorption, impeller deformation and impeller cracking. In some cases, the impeller could deform to a point that creates enough interference with the fuel pump body to cause the fuel pump to stop operating. An inoperative fuel pump will result in an illuminated check engine light, master warning indicators, rough engine running and an engine no start and/or vehicle stall while driving.

Toyota will be contacting owners of affected vehicles with instructions to return to their dealerships to have the low pressure fuel pump assembly replaced. Toyota’s numbers for this recall are 21TB05 and 21TA05. The NHTSA campaign number is 21V-617.