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

Houston – Sept. 12, 2017 – 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.

Timeline of Events

Quality assurance personnel for GST recently reviewed the structural integrity of cross-bar assemblies attached to 2017 Toyota Highlander SUVs. These inspections revealed that cross-bar fasteners had not been properly torqued during installation. GST personnel then inspected production records and torque value notations, some of which appeared to be missing. This prompted the Toyota distributor to launch an official safety recall.

GST notified associated dealers Aug. 30.

The Solution

GST has directed dealers to inspect the roof cross bars on affected vehicles and torque the fasteners if necessary, according to a recall acknowledgment document from the NHTSA. Dealers are to perform these repairs free of charge. GST plans to contact owners Sept. 25. Those in need of more immediate assistance can contact company customer service personnel at (800) 444-1074 or call the NHTSA Vehicle Safety Hotline at (888) 327-4236.

Novi, Mich. – Aug. 28, 2017 – Hino Motor Sales USA, a subsidiary of the Toyota Motor Corporation, has recalled dozes of industrial vehicles possibly equipped with improperly installed door bolts, according to documentation filed with the National Highway Transportation Safety Administration. The campaign affects 2018 NE8J, NJ8J and NV8J models. The automotive company believes 99 percent of the vehicles involved in the recall contain the defective parts.

The Defect

The models named in this latest campaign could be equipped with doors that feature upper hinges with loose bolts. This can cause the doors to function improperly and, in some cases, completely detach, creating a serious safety hazard for drivers and passengers. However, Hino has yet to receive any reports connecting the doors to accidents or injuries.

Timeline of Events

On June 13, 2017, the U.S. Hino assembly plant received prefabricated vehicle cabs from a supplier in Japan. Engineers immediately noticed structural issues with the doors on these fixtures and identified the root cause: misaligned door hinges.  Roughly one month later, the vehicle manufacturer began an internal repair initiative aimed at the hinges on assembled vehicles. This process involved installing shoulder-less bolts, repositioning cab doors by hand and tightening the bolts with the appropriate amount of torque. On July 19, the company adopted an alternative workflow due to high repair backlog, moving to an assembly-line based process that included the installation of shoulder-less hinges, along with a manual door adjustment – using a wedge – and bolt tightening. This last step was carried out with the wedge in place to ensure door fit, according to internal documentation filed with the NHTSA.

On July 28, quality assurance personnel performed spot checks on vehicles with reinstalled doors and discovered assembly errors. Specifically, assembly and repair teams at the Hino production facility had failed to apply enough to torque when installing the hinge bolts, leaving them loose. Shipments were immediately halted. Over the next two days, engineers at the site repaired the vehicles with the amended door hinges by removing the hinges. On July 31, the Hino QA division elected to launch an official safety recall to address the issue.

The vehicle manufacturer has introduced new production processes designed to prevent additional errors.

The Solution

Hino has ordered dealers to tighten the door bolts on affected vehicles, free of charge. The automaker has not yet announced when it will contact owners, according to documents submitted to the NHTSA. Owners in need of more immediate assistance can contact Hino customer service at (248) 699-9300 or connect with the NHTSA Vehicle Safety Hotline at (888) 327-4236.

Fox News – June 2, 2017

Toyota recalls 36,000 Tacoma pickups for stalling risk

Toyota is recalling 36,000 Tacoma pickups in North and South America because they can stall without warning.
The recall involves Tacomas with V-6 engines from the 2016 and 2017 model years. Most of the trucks — 32,000 — are in the U.S. The rest are in Canada, Mexico, Bolivia and Costa Rica.
The company says an engine crankshaft timing rotor may have been produced with excessive anti-corrosion coating, which could cause the crank position sensor to malfunction.
If the sensor malfunctions, the vehicle may run roughly, misfire or stall.
Toyota Motor Corp. won’t say if there have been any reports of injuries or accidents related to the defect…

Read the entire article on the Fox News website

Torrance Calif. — Feb. 14, 2017 — Some of the 2016 and 2017 Toyota Tundra vehicles produced in recent years could be subject to a new recall for exterior issues that could affect safety. Late in January, a safety recall report appeared online in the National Highway Traffic Safety Administration recall database, describing an ongoing effort.

The Defect

According to the report, the issue involved bumper resin brackets on the rear steps of these vehicles. These brackets may not be able to withstand some damage, the source said, and could weaken the bumper, causing it to fall off if someone stepped on it. The problem seems to stem, at least in part, from the use of ineffective brackets, and affects 72,847 vehicles produced within a time span of more than a year, from July 29, 2015 to Dec. 22, 2016.

Timeline of Events

• Early 2016: Although a Toyota field report claimed that a customer had broken off a piece of a vehicle bumper, the company was unsure of the source of the defect and determined that it was not due to “external influence,” according to an official chronology.
• Mid 2016 to Early 2017: Further investigation by the company revealed the link between initial damage to bumper brackets and subsequent damage to the bumper itself. More reports about this issue also spurred Toyota’s efforts to discover the cause, eventually leading to 40 total related warranty claims (only seven of which are confirmed).
• Early 2017: The recall safety campaign was confirmed Jan. 18 and the manufacturer reported it Jan. 24. The Recall Acknowledgement letter submitted to the NHTSA is dated for Feb. 6, 2017.

The Resolution

While the dealer notification date has already passed, the owner notification dates were listed to fall between Feb. 15 and March 25, 2017.  The remedy will reportedly involve replacing the bumper tread covers in affected vehicles, as well as steel brackets to replace those made of resin.

Nov. 22 – Torrance, California – Toyota recently announced a recall of Sienna minivans in response to electrical problems that may affect the operation of power sliding doors.

The Defect

According to documents compiled by the National Highway Traffic Safety Administration, the problem appears to have affected Sienna vehicles from the 2011-2016 model years – specifically, those manufactured between Jan. 4, 2010 and Aug. 12, 2016. The issue can arise when something impedes the normal operation of the power sliding doors, such as ice in the winter. When this happens, the motor stalls, generating current and operating the fuse for the door motor. There is a chance that this can cause the door to open unexpectedly while the vehicle is moving.

Timeline

January 2014  – April 2015 – Toyota first received reports of a malfunctioning door from a dealer. While an initial inspection found that the door cable was not attached to the latch mechanism, the parts still functioned normally when reattached and no abnormalities in the cable installment process were found. At the time, Toyota concluded that this was an isolated incident.

November 2015 – April 2016 – Toyota received more reports of similar issues. In some vehicles, the sliding doors refused to latch. Two reports indicated that doors opened while the vehicles were moving. Further investigation determined that these problems tended to emanate from cold climates.

May 2016 – November 2016 – Toyota determined that freezing could cause the sliding door motor to stall, leading to further malfunctions down the road. The company then announced its voluntary safety recall campaign.

Solution

Toyota will mail notices to affected vehicle owners by Jan. 21, 2017. This letter will include instructions for those owners who have already paid for repairs and wish to apply for reimbursement from the automaker.