Laguna Hills, CA – July 26, 2019 – Toyota Motor Corporation is recalling certain Prius C models due to a performance and safety issue that may prevent the vehicle’s battery from working when the automobile is in drive mode, increasing the risk of a crash for users of 2018 and 2019 models. Given this is one of several recalls affecting the company’s popular hybrid over the past five years, Toyota urges Prius C owners to get in touch with their local dealer so this issue can be corrected if this or another flaw exists. Toyota hasn’t yet officially informed registered owners of this potential hazard, but will make them aware via first-class mail Aug. 12. Safety-related automotive recalls are free of charge, and this one is no exception.

The Defect

As documented by the National Highway Traffic Safety Administration, Toyota is recalling approximately 464 2018-2019 Prius C vehicles. The problem affecting a limited number of these hybrid automobiles is related to its propulsion system. Apparently, the auxiliary battery, which comes standard in all Priuses, may not receive the power it needs to propel the vehicle forward because of a flaw within the circuit board, which may have occurred at some point during the manufacturing or assembly process. If the transistor to the circuit board were to separate, the battery may lose its ability to energize the vehicle. This of course presents a safety hazard for Prius C owners as well as others on the road should this malfunction occur, especially when moving at a high rate of speed.

Timeline of Events

Unlike other recalls cleared with the NHTSA, which tend to be more isolated in nature, this isn’t the first affecting the Prius. As reported by the Los Angeles Times and other media outlets, an estimated 20,000 Prius owners have reported power system failures tracing back to 2014. At that time, over 800,000 Priuses were pulled from the market because of a glitch with the vehicle’s inverter transistors, which also impacted propulsion and the potential for the automobile to suddenly power down. This recall affected C models manufactured between 2010 and 2014. Another recall was ordered last October to correct certain power failures that the original recall didn’t address.

This most recent recall is different in a couple of respects. First, it pertains to 2018 and 2019 models and it’s much smaller. Indeed, Toyota believes that of the 464 vehicles included in the recall, likely only 10% have the defect. This is partially due to the DC-DC converter that is exclusive to those Prius C vehicles built between February 2018 and October of the same year.

The Solution

Even though there may be no immediate signs of separation, the propulsion issue may develop over time, depending on how frequently Prius owners drive and how many years they go before buying a new or used vehicle. Given this, Toyota is making this move out of an abundance of caution. The company says it will formally inform owners of the safety concern by mail starting in mid-August and will encourage drivers to take their automobile back to the dealer from which they purchased it or to any authorized Toyota dealership. If it’s deemed appropriate, the DC-DC converter will be replaced with an alternative unit, which will come at no cost to the owner for parts or labor.

As previously referenced, this latest is recall is one of several for Prius models. If you own one that’s 10 years or older, visit MotorSafety.org. By entering your VIN information, you can find out if your subject to this or some other recall order.

Laguna Hills, CA – March 21, 2019 – Toyota is recalling certain 2019 Camry Hybrid and Avalon Hybrid vehicles. The fuel filler pipe may have been incorrectly refastened to the fuel tank during a safety inspection after the vehicle was assembled. The improperly connected component may leak fuel, which could catch fire if a spark or ignition source is nearby. As many as 205 vehicles may be affected by this issue.

The Defect

According to the National Highway Traffic Safety Administration Safety Recall Report on this issue, the fuel filler pipe may not have been properly reconnected to the fuel tank during an inspection after vehicle assembly. As a result, the improperly connected filler pipe could leak fuel, resulting in an increased risk of fire.

Timeline of Events

Toyota received two reports from dealers in January 2019 describing fuel leaking underneath the vehicle during refueling. The automaker began an investigation into the issue and found that the vehicles in these two reports had been part of a group of vehicles involved in an inspection for potential replacement of the fuel filler pipe prior to dealer delivery. The inspection was described as a quality confirmation activity.

Toyota then began a field survey to inspect additional vehicles that had been part of this quality confirmation activity. As a result of the survey, two additional vehicles with the same disconnected fuel filler pipe issue were identified.

Based on the investigation, quality confirmation activity team interviews and a review of the vehicle design drawings, Toyota determined that the vehicles did not meet certain U.S. federal motor vehicle safety standard requirements, and so decided to conduct a recall beginning in March 2019.

The Solution

The recall will begin March 2019. Toyota will notify all known owners of affected vehicles by April 15, 2019. Owners will be told to return their vehicles to a Toyota dealer for inspection of the fuel filler pipe. If it turns out that the pipe had been improperly connected or unsecured, the dealer will replace the fuel filler pipe with a new one at no cost, as the repair would be covered under Toyota’s new vehicle warranty.

Owners may contact Toyota customer service at 1-888-270-9371. Toyota’s number for this recall is K0I. Owners may also contact the NHTSA Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.safercar.gov. The NHTSA Campaign Number for this recall is 19V097000.

Plano, Texas – January 30, 2019 –  Toyota is recalling close to 3,400 2019 Toyota Corolla hatchbacks in the USA and a further nearly 1,000 vehicles in Canada due to a faulty component in the transmission. Only Corolla Hatchbacks with a continuously variable transmission (CVT) are included in this recall. The Corolla sedan is excluded, as are any hatchbacks with manual transmissions.

The Defect

According to Toyota’s press release, in the involved vehicles, there is a possibility the that due to a manufacturing error, the blades of the pump impeller in the torque converter may detach, causing the converter in Toyota’s Continuously Variable Transmission (CVT) to possibly fail. This may lead to a loss of vehicle power. If the part fails while the car is in motion, the vehicle’s loss of power could increase the risk of a crash, especially if the failure happens when the vehicle is traveling at a high speed, which could lead to a crash or possible vehicle rollover or even an explosion due to catastrophic transmission failure.

Timeline of Events

In July of 2019, more than 1000 Toyota Models were recalled due to a labeling error. A subsidiary of Toyota Motor Company recalled certain Corolla, Sienna, Yaris iA, and Camry models due to a labeling flaw that may misinform users of how much weight their automobiles can safely carry. Motorists should check the label on their factory-installed floor mats to see if they’re affected and contact their nearest Toyota dealership so the clerical issue can be corrected. The replacement will come at no charge.

Late in 2018 a previous Toyota recall revealed that over 130,000 of its trucks and SUVs had faulty sensors, affecting seat belt tension and air bag functionality. At the time no plan was in place to resolve that issue, although Toyota announced in a press release that it was developing a solution and would notify owners by mid-February.

The news of the pending recall came in late December. It has not yet been released what prompted the investigation that led to the recall, although at this time no accidents or injuries related to the vehicles being recalled are known as yet. Toyota introduced its new “Direct Shift-CVT” in 2018 and implemented it in the 2019 Corolla Hatchback. The Direct Shift-CVT uses a launch gear to improve off-the-line performance. The expectation was that the addition would lead to faster shifts and a 6 percent increase in fuel economy.

The Solution

Toyota dealers will replace the Direct Shift-CVT with a new one containing a new torque converter not affected by this issue at no cost to customers, starting as soon as the company has sufficient parts to make those repairs.

Owners can contact Toyota at 800-331-4331. Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.safercar.gov.

Laguna Hills, CA – December 31, 2018 – Toyota Motor Engineering & Manufacturing (Toyota) is recalling certain 2018-2019 Toyota Tacoma vehicles due to a potential brake issue. Toyota estimates that at least 90 percent of the involved vehicles have potential to develop the failed seal condition over the lifetime of the vehicle, which could lead to the unreasonable risk to safety. The potential number of units affected is 44,121.

The Defect

According to the NHTSA Recall Safety Report, the vehicles contain a brake master cylinder that includes a rubber seal which seals the brake fluid within the housing as the master cylinder piston moves. Due to combinations of improper part machining operations at one supplier facility and casting variations of master cylinders at another of its facilities, there is a possibility that a master cylinder could have an edge that does not have the correct chamfer where the rubber seal is retained. If this were to occur, over time, this edge could damage the rubber seal, causing an internal fluid leak. If the vehicle continues to be operated in this condition, the brake pedal feel could change, and front brake performance could be suddenly reduced. Reduced front braking performance could increase the vehicle stopping distance and may increase the risk of a crash.

Timeline of Events

According to the chronology report issued by Toyota, in June 2018, Toyota received three field reports on 2018 Tacoma vehicles which described the brake pedal traveling to the floor and reduced braking ability. All three of these vehicles had less than 600 miles. The brake master cylinders were recovered and sent to the part supplier for investigation. In August, Toyota received additional field reports of this condition, which master cylinders were also recovered and sent to the supplier for investigation. In September, the part supplier began providing its preliminary analysis based on some of the recovered parts. This preliminary analysis indicated that an internal leak existed which was caused by a cut rubber seal, and it was observed in these cases that the channel within the bore of the master cylinder, which is designed to retain the rubber seal, had an edge that did not have the correct chamfer.

Between October 2018 – early December 2018, the part supplier reported that their testing had identified multiple improper processes completed at the U.S. machining facility. When some combination of these improper processes were applied to non-concentric castings from the supplier casting facility in Japan, there existed a possibility of producing master cylinders with edges at the channel of the bore with varying levels of incorrect chamfer. It was also determined that this would only occur on parts cast in the supplier’s Japan facility and machined at the supplier’s U.S. facility.

Additional testing on newly machined master cylinders with edges of different incorrect chamfers revealed that the seals in a number of these tests were damaged and may eventually result in an internal leak. Any parts which were cast in the supplier’s Japan facility and machined in the supplier’s U.S. facility during the production range preceding identification of a potential issue may have some level of incorrect chamfer which may damage the seal.

It was determined that a damaged seal could cause brake fluid to leak internally, causing the brake pedal feel to change, and front brake performance could be suddenly reduced. On December 7, 2018, based on the results of the above investigation, Toyota decided to conduct a voluntary safety recall campaign. As of December 3, 2018, Toyota was only aware of 5 Toyota Field Technical Reports (3 unconfirmed reports) and 37 warranty claims (28 unverified claims) received from U.S. sources which were considered in the recall decision. Toyota is unaware of any accidents or injuries.

The Solution

All known owners of the involved vehicles will be notified via first class mail to return their vehicles to a Toyota dealer. Toyota dealers will replace the brake master cylinder with a new one, free of charge. As the owner notification letters will be mailed out well within the active period of the Toyota New Vehicle Limited Warranty (“Warranty”), all involved vehicle owners for this recall would have been provided a repair at no cost under Toyota’s Warranty. The recall is expected to begin January 21, 2019. Owners may contact Toyota customer service at 1-888-270-9371. Toyota’s numbers for this recall are J16/J06. Owners may also call the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153). The NHTSA Campaign Number for this recall is 18V-888.