Plano, Texas – Jan. 18, 2018 – Toyota Motor Engineering & Manufacturing recently issued a recall of nearly 650 vehicles across a number of its most popular models over concerns that a software error led to incorrect information being printed on capacity labels, according to a filing made with the National Highway Traffic Safety Administration.

The recall includes the following types of Toyota vehicles:

• 4Runner light SUVs produced in the 2017 and 2018 model years, produced from July 11 to Oct. 6, 2017.
• Highlander SUVs from the 2018 model year produced between Oct. 24 and 26, 2017.
• RAV4 light SUVs from the 2018 model year produced from Sept. 11 to 25, 2017.
• Sienna minivans from the 2017 model year, produced on Oct. 12, 2017.
• Tacoma trucks from the 2017 model year, produced from July 11 to Nov. 2, 2017.
• Tundra trucks from the 2017 and 2018 model years, produced from July 11 to Nov. 4, 2017.

The recall also includes Lexus GX460 SUVs from the 2018 model year, produced from Aug. 9 to Oct. 20, 2017.

The Defect

Due to the programming error, which led to incorrect accessory weight calculations, labels about the vehicles’ load-carrying capacities were printed with the incorrect information. That issue, in turn, means the vehicles do not meet basic Federal Motor Vehicle Safety Standards requirements. Moreover, drivers who overload their vehicles based on the inaccurate information could increase their risk of a crash.

All vehicles in the recall are expected to carry this defect, but not all of them were sold in the U.S.

Timeline of Events

In late November, Toyota received information from a vehicle processing center that indicated a number of trucks and SUVs had been given load-carrying capacity labels with inaccurate information, and the issue was quickly tracked back to a software error that was corrected in short order.

The company then determined that the affected period in which the incorrect information was being printed lasted from Sept. 7 to Nov. 17, 2017 and conducted a review of affected vehicles based on their vehicle identification numbers to determine the extent of the issue and find out whether the software error resulted in noncompliance with the FMVSS.

On Dec. 14, 2017, Toyota noted that the incorrect labels did put the vehicles outside FMVSS requirements and initiated the recall.

The Solution

Toyota has already begun mailing replacement labels and instructions to owners of affected vehicles via first-class mail. Because all these vehicles were still under their New Vehicle Limited Warranties, the company would have covered any associated repair costs free of charge.

The automaker notified dealers of the recall on Dec. 20, 2017, and planned to mail the replacement labels and instructions to vehicle owners from Jan. 15, 2018 to Feb. 18, 2018.

Deerfield Beach, Florida – Dec. 19, 2017 – Southeast Toyota Distributors, LLC, recently issued a recall for 431 Toyota 4Runner sport utility vehicles from model years 2015 to 2018, citing concerns over the front grille of the vehicles, according to the National Highway Traffic Safety Administration.

The recall revolves around billet grille overlay kits sold by Southeast Toyota Distributors with U-nuts that can fracture, potentially leading the overlay to detach from the grille itself and potentially lead to a road hazard for following traffic. That, in turn, can increase the risk of crashes and injuries.

In all, 100 percent of the recalled vehicles are expected to have this issue, one from the 2015 model year, five from 2016, and the rest from either 2017 or 2018. These vehicles were produced from Dec. 5, 2014, to Oct. 26, 2017.

The Defect

Southeast Toyota Distributors began receiving accessory billet grille overlays in October 2014, but in mid-July 2017 those kits began coming with revised U-nuts treated with phosphate. Soon after, the organization began receiving reports from technicians about fractures, as well as two field reports in which the U-nuts fractured. However, only the newer U-nuts have reportedly fractured.

Timeline of Events

In November 2017, reports of these issues started to come into Southeast Toyota Dealers, leading to the company contacting the grille overlay supplier, T-Rex Truck Products in Corona, California. However, neither company could replicate the conditions that led to the phosphate-treated U-nuts fracturing, even when applying torque above and beyond normal conditions. Despite that, SET has issued a recall for all vehicles with the grille overlay made since the revised U-nut was added to the kit.

Beginning Nov. 20, the parts supplier is issuing new hardware for the grille overlay kits.

The Solution

SET is currently working with IHS Automotive to get as much current contact information for owners of the 4Runners in the recall, and will mail recall notification letters on or around Jan. 26, 2018. Dealers were already notified in late November.

Owners who take the vehicles into local dealerships will have the U-nuts replaced with upgraded hardware free of charge.

Plano, TX – Nov. 30, 2017 – Toyota Motor Engineering and Manufacturing has recalled more than 39,000 vehicles potentially equipped with defective fuses, according to documentation submitted to the National Highway Transportation Safety Administration. The campaign affects 2012-2015 Toyota Prius PHV plug-in hybrid sedans manufactured between July 20, 2011 and Jan. 8, 2015. Toyota is unsure what percentage of the vehicles referenced in the recall actually contain the defective components.

The Defect

The affected sedans may contain electric vehicle fuses prone to fracture following excessive thermal stress. Normally, this condition develops during high-load driving maneuvers such as prolonged ascents. In instances in which the fuse fractures and subsequently opens while in operation, the vehicle may lose power or continue to function but with reduced capacity. This defect poses a serious risk to owners, as the sudden loss of motive power could increase the likelihood of an accident. However, Toyota has yet to receive reports linking the damage-prone fuse to any accidents or injuries.

Timeline of Events

Toyota received a field report from the European market in August 2014 detailing an instance in which a Prius PHV sedan lost motive power, triggering interior warning lights, according to a chronology document submitted to the NHTSA. A dealer determined that the hybrid battery was the root cause of the event and installed a replacement, eventually sending the damaged original to the Toyota home office for further evaluation. Here, engineers found that the EV fuse was fractured and ultimately attributed the problem to an installation error. Toyota reviewed its production processes and eventually determined the fuse was bent during manufacturing, inhibiting its durability. The automaker updated its processes to prevent similar problems in February 2015.

In March 2015, Toyota received additional reports from the U.S. market. Engineers for the company inspected fuses from six vehicles, four of which showed signs of fracturing. Toyota began to consider that these defective parts were not the result of flawed manufacturing workflows, but the product of deeper mechanical issues, specifically excessive current generated during high-load driving. However, the car company could not replicate the issue in-house and put a hold on ongoing investigations related to the defective fuses in June 2017.

Then, one month later, another report came in outlining a situation in which an owner in Japan lost motive power in the middle of an intersection. The EV fuse installed in the vehicle was fractured. The driver told Toyota officials that he frequently drove up inclines under electric power only. Engineers attempted to replicate the problem by driving the exact same route the owner had driven but were once again unable to do so. However, they did record data that indicated prolonged large current flow. This information led them to perform additional tests during which vehicles were subjected to multiple slow-speed ascents. During these trials, the engineers were able to replicate the fuse fracture.

On Nov. 9, 2017, Toyota launched a voluntary safety recall to address the issue. The automaker notified dealers Nov. 14.

The Solution

Toyota has directed dealers to replace the EV fuses in affected vehicles free of charge, according to an NHTSA recall acknowledgement document. The car manufacturing company intends to notify owners via first-class mail Jan. 8, 2018. Those in need of more immediate assistance can contact Toyota customer service personnel at (800) 331-4331. Callers should use the internal recall identification code H0R. Owners can also contact the NHTSA directly using the toll-free Vehicle Safety Hotline at (888) 327-4236.

Torrance, Calif. – Nov. 7, 2017 – Toyota Motor Engineering and Manufacturing has recalled a handful of hybrid vehicles with defective inverter assemblies, according to documentation submitted to the National Highway Transportation Safety Administration. The campaign affects 2016 Toyota Prius hybrid sedans produced between Dec. 15, 2015 and June 8, 2016. Toyota is unsure how many of the recalled models contain defective parts.

The Defect

The vehicles referenced in the action come equipped with inverter assemblies whose capacitors may not be properly secured to the inverter housing. This assembly flaw leaves the capacitor terminal vulnerable to damaging vibration during vehicle operation, increasing the likelihood of a complete hybrid system shutdown. In the event that this occurs, the vehicle loses all motive power, creating a serious safety hazard for occupants. While capacitor terminal damage results in engine shutdown, the power steering and braking systems continue to function normally.

Toyota has yet to receive field reports detailing any accidents or injuries.

Timeline of Events

In April 2017, the automaker received a report from a U.S. dealer detailing an instance in which a 2016 Prius failed to failed to start, according to an internal document submitted to the NHTSA. Toyota engineers recovered and inspected the inverter assembly in the vehicle, and found that capacitor mounting bolts were missing. They also discovered that the capacitor itself had incurred terminal damage. The car company launched an investigation to determine how the capacitor bolts had gone missing, focusing on production data and records of the inverter installation process. Toyota found that the inverter assembly had been reworked during capacitor installation and that personnel had failed to re-install the bolts. Toyota soon amended its capacitor installation workflow to prevent similar scenarios from unfolding in the future.

In July 2017, engineers at the vehicle manufacturing company initiated replication tests to better understand the capacitor terminal damage observed in the vehicle in the report. Staff simulated operational vehicle vibration and applied it to the inverter assembly with the unbolted capacitor. Toyota found that the capacitor was prone to damage in these conditions. It initiated bench testing in an attempt to replicate the engine failure mentioned in the report, but was unable to do so.

One month later, Toyota received a report from the European market outlining events similar to those detailed in the April report from the U.S. market. Toyota recovered the inverter assembly from the vehicle referenced in the report and found that capacitor mounting bolts were missing. The capacitor terminal had sustained significant damage. Resin from another nearby part also melted within the inverter housing. Toyota installed the inverter assembly in a trial vehicle to see if the component, when stressed, led to complete engine shutdown. During the subsequent test, the trial vehicle lost all motive power, as the hybrid system ceased operation. The car company disassembled the inverter assembly used in the trial car and found that the capacitor terminal had sustained further damage.

With these results in hand, Toyota officials concluded that vehicles with inverter assemblies that lack capacitor mounting bolts are vulnerable to complete engine shutdown. On Oct. 12, the car company chose to conduct a voluntary safety recall. As of that date, Toyota had received one warranty claim and zero technical field reports related to the defect from dealers in the U.S. market. Dealers received notification Oct. 18.

The Solution

Toyota has instructed dealers to replace the inverter assemblies in affected vehicles free of charge, according to an NHTSA recall acknowledgment document. The organization plans to notify owners via telephone in December. Those in need of more immediate assistance can connect with Toyota customer service staff at (800) 331-4331. Callers should use the internal recall identification code H0U. Owners can also reach out the NHTSA directly using its toll-free Vehicle Safety Hotline at (888) 327-4236.

Recall Masters -September 12, 2017

Toyota recalls SUVs with defective roof accessories

Gulf States Toyota, the second-largest distributor of Toyota vehicles worldwide, has recalled more than 1,100 sport utility vehicles possibly equipped with defective roof rail accessories, according to documentation filed with the National Highway Transportation Safety Administration. The campaign affects 2017 Toyota Highlander and Highlander Hybrid models with production dates ranging from Nov. 16, 2016 to July 19, 2017. The car company suspects 100 percent of the vehicles referenced in the recall contain the defective part.
The Defect
The models named in the recall are equipped with roof rail cross bars with fasteners that were not tightened properly during the installation process, which took place at GST headquarters. Consequently, the fasteners could become loose during operation, possibly leading to complete cross-bar detachment. This poses a serious safety risk to owners. However, the GST has yet to receive reports detailing instances of detachment or linking the defective accessory to accidents or injuries…

Read the entire article on the Recall Masters website