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.

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.

Toyota will be contacting the owners of certain 2019-2020 Rav4 and Rav4 Hybrid vehicles because of a problem that could exists with the front lower suspension.

According to the defect report, the lower suspension arms connecting the front wheels to the vehicle front cross member may be defective due to improper production conditions at the steel supplier. If a vehicle with an affected suspension arm is repeatedly driven with rapid acceleration and deceleration, it is possible that cracks could propagate throughout the arm, causing it to eventually separate from the front wheel assembly. The problem could result in loss of vehicle control and an increased risk of a crash.

Owners receiving notices will be asked to return to their dealers to have both front lower suspension arms replaced. Toyota’s interim numbers for this recall are 20TB08 / 20TA08 and the NHTSA campaign number is 20V-286.

Toyota will be contacting the owners of certain 2020 Corolla vehicles because of an electrical problem that could cause the backup lights to fail.

The vehicles affected are equipped with a rear hatch that contains a wire harness for rear end electrical components. During the inspection process, damaged testing equipment may have caused the contact gaps of the wire harness connector to increase. Lower contact pressure inside the connector increases the chances of an oxide layer developing on the surface of certain terminals. Over time the electrical resistance could increase, resulting in loss of backup lamps. If the lamps do not illuminate when the vehicle is backing, there is an increased risk of a crash.

Those receiving notices can return to their dealerships to have the rear hatch wire harness replaced. Toyota’s numbers for this recall are 20TB07 and 20TA07 and the NHTSA campaign number is 20V-205.

Toyota will be contacting the owners of certain 2020 Highlander vehicles equipped with 3.5 L, V6 (2GR-FKS) gasoline engines that contain the Stop & Start Engine System that monitors your brake pedal operation to stop your engine when the vehicle is stopped.

The vehicles involved contain an engine control unit (ECU) programming error that may not correctly supply fuel to the engine when this feature is activated. The problem could result in an unexpected stall followed by an audible chime and multiple warnings indicating the engine has stalled.

Dealers will correct the problem by reprogramming the ECU. Toyota’s number for this recall is 20TA06 and the NHTSA campaign number is 20V162.

Click here to view the complete 2020 Toyota Highlander recall notice.

Toyota will be contacting the owners of certain Toyota and Lexus vehicles because of a problem affecting engine and engine cooling. The subject vehicles are equipped with 2.5L 4 cylinder engines that may have been produced with engine blocks with high porosity levels.

According to the defect report, these porous engine blocks could crack and leak internally and/or externally causing the engine to overheat and possible internal mechanical damage. There is also an increased risk of an engine fire if oil leaks should come in contact with an ignition source.

Drivers may be alerted of a problem through engine noises, smoke, illuminated engine warning lights and an audible warning chime.


Vehicles Affected
2020 Lexus ES300H
2020 Toyota Avalon Hybrid
2020 Toyota Camry
2020 Toyota Camry Hybrid
2019-2020 Toyota RAV4
2019-2020 Toyota RAV4 Hybrid

Dealers will inspect the engine and engine block, replacing them as necessary. Toyota’s number for this recall is 20TA04. Lexus’ number for this recall is 20LA02. The NHTSA campaign number is 20V-064.

Toyota will be contacting the owners of certain Avalon, Corolla and Matrix cars because of a problem that could result in the air bags and seat belt pretensioners not deploying.

According to the defect report, the affected vehicles may have been manufactured with an airbag control module that does not have sufficient protection against negative electrical transients generated in certain severe crashes where there is a large engine compartment intrusion before deceleration. In these cases, the crash sensor and wiring may be damaged and shorted before the deployment signal is received by the SRS ECU. This would result in incomplete or non deployment of the air bags and/or pretensioners and an increased chance of injury to occupants.

Vehicles Affected
2012-2018 Toyota Avalon
2013-2018 Toyota Avalon Hybrid
2011-2019 Toyota Corolla
2011-2013 Toyota Matrix

Owners will be notified to return to their Toyota dealer to have a noise filter installed between the airbag control module and its wire harness. In some cases, an inspection may be carried out to determine if a noise filter is necessary before installing it.

Toyota will be contacting the owners of certain 2019-2010 Toyota and Lexus vehicles regarding a problem affecting the braking and stability control systems. The vehicles involved include:

  • 2019 Lexus ES300H
  • 2019 Lexus LC500
  • 2019 Lexus LS500
  • 2019 Lexus LS500 H
  • 2019 Lexus U250 Hybrid
  • 2020 Toyota Corolla Hybrid
  • 2019 Toyota Prius
  • 2019-2020 Toyota Prius Prime
  • 2019 Toyota Rav4 Hybrid

The affected vehicles have a brake booster pump with an accumulator and a pump motor which contains a plastic brush holder to hold the motor brushes. It is possible that the plastic brush holder may have been manufactured improperly, causing one of the brushes to become stuck in the brush holder. If this happens, the brush would be unable to maintain an electrical connection inside the motor and may cause the pump motor to stop operating.

If the pump motor stops operating, multiple warning lights and messages will illuminate, and/or audible chimes will sound. Depending on brake fluid pressure in the accumulator and brake pedal stroke amount, braking assist could be lost completely and the Vehicle Stability Control system will become deactivated. A sudden and complete loss of braking assist while driving could increase the vehicle stopping distance and may increase the risk of a crash. Further, deactivating the Vehicle Stability Control system may cause the subject vehicles to not meet the requirements of FMVSS No. 126, paragraph S5.1.2.

Owners receiving notices will be asked to return to their dealers to have the brake booster pump inspected and replaced as necessary. Toyota’s numbers for this recall are K1L/K0L. Lexus’ numbers for this recall are K2F/KLF. The NHTSA Campaign Number is 19V544000.