RECALL 22LA02 – Potentially Missing Spot-Welds – 2022 Lexus

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April 13, 2022 NHTSA CAMPAIGN NUMBER: 22V238000

Missing Welds May Cause Shock Absorber to Separate

A separated shock absorber can cause a loss of vehicle stability, increasing the risk of a crash.

 

NHTSA Campaign Number: 22V238

Manufacturer Toyota Motor Engineering & Manufacturing

Components STRUCTURE, SUSPENSION

Potential Number of Units Affected 4,215

 

Summary

Toyota Motor Engineering & Manufacturing (Lexus) is recalling certain 2022 NX250, NX350, NX350h, and NX450h+ vehicles. Missing spot-welds between the body panels and the front shock absorber mounting areas may cause the front shock absorber to separate from the mounting area.

 

Remedy

Dealers will add welds to body panels or replace the body panels where welds have failed, free of charge. Owner notification letters were mailed on June 10, 2022. Owners may contact Lexus customer service at 1-800-331-4331. Lexus’s number for this recall is 22LA02.

 

Notes

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.nhtsa.gov.

 

Check if your Vehicle has a Recall

 


Description of Corrective Repair Action:

All known owners of the subject vehicles will be notified to return their vehicles to a Lexus dealer. For all involved vehicles, Lexus dealers will inspect for the presence of spot-welds around the front shock absorber mounting areas. For vehicles with missing spot welds, additional welds will be added to the body panels. If the inspection determines that the body panels or any welds have failed, the body panels will be replaced.

 


Certain 2022 Model Year NX 250, NX 350, NX 350H, NX450H+
Potentially Missing Spot-Welds

Model / Years Production Period Approximate Total Vehicles Approximate Stop Sale Dealer Inventory
2022 NX 250 Late May2021 – Late January 2022 600 1
2022 NX 350 Early April 2021 – Late January 2022 2500 10
2022 NX 350H Early April 2021 – Late January 2022 800 0
2022 NX 450H+ Early April 2021 – Late January 2022 400 1

 

STOP! DO NOT SELL NEW VEHICLES IN DEALER INVENTORY.

Refer to Dealer Inventory Procedures section for more details.

 

On April 13, 2022, Lexus will file a Defect Information Report (DIR) with the National Highway Traffic Safety Administration (NHTSA) informing the agency of our intent to conduct a voluntary Safety Recall on 2022 model year NX model vehicles.

 

Condition

The front shock absorbers in the affected vehicles are mounted to body panels that may be missing some spot-welds. Incorrect welding could eventually cause a shock absorber to separate from the mounting area, resulting in a loss of driving stability and increasing the risk of a crash.

 

Remedy

For all involved vehicles, Lexus dealers will inspect the welding near the shock absorber mounting area. For vehicles with missing spot welds, additional welds will be added to the body panel(s) FREE OF CHARGE. If the inspection determines that any welds on the right or left body panel have failed, the body panel with the failed weld(s) will be replaced with a new body panel FREE OF CHARGE.

 

Covered Vehicles

There are approximately 4,300 vehicles covered by this Safety Recall. Approximately 70 vehicles involved in this Safety Recall were distributed to Puerto Rico.

 

Owner Letter Mailing Date

Lexus will notify owners by the middle of June 2022.

Lexus makes significant effort to obtain current customer name and address information from each state through industry resources when mailing owner letters. In the event your dealership receives a notice for a vehicle that was sold prior to the Safety Recall announcement, it is the dealership’s responsibility to forward the owner letter to the customer who purchased the vehicle.

Please note that only owners of the covered vehicles will be notified. If you are contacted by an owner who has not yet received a notification, please verify eligibility by confirming through TIS prior to performing repairs. Dealers should perform the repair as outlined in the Technical Instructions found on TIS.

 

Pre-Owned Vehicles in Dealer Inventory

To ensure customer satisfaction, Lexus requests that dealers complete this Safety Recall on any used vehicles currently in dealer inventory that are covered by this Safety Recall prior to customer delivery. However, if the campaign cannot be completed (for example, due to remedy parts availability), delivery of a covered vehicle is acceptable if disclosed to the customer that the vehicle is involved in a Safety Recall.

Lexus expects dealers to use the attached Customer Contact and Vehicle Disclosure Form to obtain vehicle buyer information. Dealers are expected to provide a copy of the completed form, along with the most current FAQ, to the vehicle buyer.Lexus and the dealer may use this information to contact the customer when the remedy becomes available.

Keep the completed form on file at the dealership and send a copy to quality_compliance@toyota.com. In the subject line of the email state “Disclosure Form 22LA02” and include the VIN.

NOTE: Dealers can identify if any of their new and used inventory has any open campaigns in the Vehicle Inventory Summary available in Dealer Daily. The Vehicle Inventory Summary may take up to 4 hours to populate information for newly launched campaigns.

 

L/Certified Vehicles

L/Certified policy prohibits the certification of any vehicle with an outstanding Safety Recall, Special Service Campaign, or Limited Service Campaign. Thus, no affected units are to be designated, sold, or delivered as an L/Certified vehicle until all applicable Safety Recalls, Special Service Campaigns, and Limited Service Campaigns have been completed on that vehicle.

 

LCCS Service Loaners

Lexus requests that dealers remove all LCCS Service Loaner vehicles from service that are covered by a Safety Recall unless the defect has been remedied.

 

Customer Contacts

Customers who receive the owner letter may contact your dealership with questions regarding the letter and/or the Safety Recall. Please welcome them to your dealership and answer any questions that they may have. A Q&A is provided to assure a consistent message is communicated.

Customers with additional questions or concerns are asked to please contact the Lexus Brand Engagement Center (1-800-255-3987) – Monday through Friday, 8:00 am to 8:00 pm, Saturday 9:00 am to 7:00 pm Eastern Time.

 

Salvage Title Vehicles

Every attempt should be made to complete an open Safety Recall when circumstances permit, unless noted otherwise in the Safety Recall dealer letter.

For complete details on this policy, refer to Lexus Warranty Policy 4.17, “What Is Not Covered by The Lexus New Vehicle Limited Warranty”.

 

Media Contacts

It is imperative that all media contacts (local and national) receive a consistent message. In this regard, all media contacts must be directed to Aaron Fowles (469) 292-1097 in Toyota Corporate Communications. Please do not provide this number to customers. Please provide this contact only to media.

 


Certain 2022 Model Year NX 250, NX 350, NX 350H, NX450H+
Potentially Missing Spot-Welds

Frequently Asked Questions

Original Publication Date: April 13, 2022

 

Q1:What is the condition?

A1: The front shock absorbers in the affected vehicles are mounted to body panels that may be missing some spot-welds. Incorrect welding could eventually cause a shock absorber to separate from the mounting area, resulting in a loss of driving stability and increasing the risk of a crash.

 

Q1a: If the condition exists, are there any symptoms/warnings that drivers might experience?

A1a: Initially, a driver may not experience any symptoms/warnings if the vehicle does not have the proper spot welding.  Over time, cracks and breakage may occur on other spot-welds and/or on the body panels around the front shock absorber mounting areas, leading to abnormal steering feeling. Under longer-term (time and mileage) use, this could eventually cause a front shock absorber to separate from the mounting area, creating an abnormal noise, and resulting in a loss of vehicle driving stability.

 

Q2: What is Lexus going to do?

A2: For all involved vehicles, Lexus dealers will inspect the welding near the shock absorber mounting area. For vehicles with missing spot welds, additional welds will be added to the body panel(s) FREE OF CHARGE. If the inspection determines that any welds on the right or left body panel have failed, the body panel with the failed weld(s) will be replaced with a new body panel FREE OF CHARGE.

 

Q3: Which and how many vehicles are covered by this Safety Recall?

A3: There are approximately 4,300 vehicles covered by this Safety Recall. Approximately 70 vehicles involved in this Safety Recall were distributed to Puerto Rico.

Model Name Model Year Production Period
NX 250 2022 Late May2021 – Late January 2022
NX 350 2022 Early April 2021 – Late January 2022
NX 350H 2022 Early April 2021 – Late January 2022
NX 450H+ 2022 Early April 2021 – Late January 2022

 

Q4: How long will the inspection take?

A4: The inspection takes approximately 45 minutes. However, depending upon the dealer’s work schedule, it may be necessary to make the vehicle available for a longer period of time.

 

Q5: How does Lexus obtain my mailing information?

A5: Lexus uses an industry provider who works with each state’s Department of Motor Vehicles (DMV) to receive registration or title information, based upon the DMV records. Please make sure your registration or title information is correct.

 

Q6: What if I have additional questions or concerns?

A6: If you have additional questions or concerns, please contact the Lexus Brand Engagement Center at 1-800-255-3987 Monday through Friday, 8:00 am to 8:00 pm, Saturday 9:00 am to 7:00 pm Eastern Time.

 


Description of Problem:

The subject vehicles are manufactured with body panels that are spot-welded to the left and right front shock absorber mounting areas.  During the spot-welding of these panels, there is a possibility that certain spot-welds were missed.  In this condition, cracks and breakage may occur on other spot-welds and/or on the body panels around the front shock absorber mounting areas.  Under longer-term (time and mileage) use, this could eventually cause a front shock absorber to separate from the mounting area, resulting in a loss of vehicle driving stability, increasing the risk of a crash.

 

Chronology of Principal Events:

January 2022 –March 2022

In late January 2022, during a sampling inspection of a vehicle body at the NX vehicle assembly plant, Toyota found that some spot-welds on the body panels around the left front shock absorber mounting area were missing.  Toyota began to investigate the welding machine and its process.

While reviewing the welding process settings, Toyota found there was a possibility that the welding machine for the left and right side of a vehicle body may not have recognized a work completion clear signal which should have been received from the process control board after the welding work was completed.  If this occurs, the welding machines would remain in a “work completed” status and would not execute the next welding operation.  Toyota updated the logic of the process control board to allow the welding machines to recognize the signal properly.  In parallel, Toyota began an investigation to determine if other vehicle bodies may have the same condition.  It was found that a small number of vehicle bodies at the plant had missing spot-welds at either the left or right front shock absorber mounting area.

Toyota conducted duplication testing on each of the welding machine to assess why the machines may not have recognized the signal from the process control board.  The left and right machines failed to recognize the signal in 5 out of 9,242 tests.  In addition, it was confirmed that, due to a variation in the signal (pulse signal) width, the pulse signal could be shorter than the recognition interval in the welding machine, causing the machine to occasionally not recognize the signal.  This further confirmed the possibility that missing spotwelds had sporadically occurred.

In February 2022, Toyota began an investigation of the potential effects that missing spot-welds might have on vehicle performance.  A CAE analysis was performed to simulate frontal collisions with missing spot-welds to evaluate the effects, if any, on vehicle crashworthiness.  It was found that the load and deformation at the front of the vehicle cabin was smaller than in a properly welded vehicle; therefore, the missing spot-welds did not negatively affect the vehicle’s crash performance.

Additionally, Toyota considered the effect of the missing welds on the vehicle driving stability.  This was evaluated using further CAE analysis and full-vehicle drive testing.  The drive testing was conducted using a new vehicle with missing spot-welds; it was found that there were no effects on vehicle driving stability.  However, based on the CAE analysis, Toyota assessed that, over time, cracks and breakage could occur on other spot-welds and/or on the body panels around the front shock absorber mounting areas.  Toyota believed, under longer-term use (time and mileage), this could eventually cause the front shock absorber mounting panel to separate from the mounting area, which could result in a loss of vehicle driving stability and increase the risk of a crash.

 

April 7, 2022

Based on the results of the above investigation, Toyota decided to conduct a voluntary safety recall campaign.

As of April 6, 2022, based on a diligent review of records, Toyota’s best engineering judgement is that there are 0 Toyota Field Technical Reports and 0 warranty claims that have been received from U.S. sources that relate or may relate to this condition and which were considered in the decision to submit this report.

 

Description of Corrective Repair Action:

All known owners of the subject vehicles will be notified to return their vehicles to a Lexus dealer.  For all involved vehicles, the dealers will inspect for the presence of spot-welds around the front shock absorber mounting areas.  For any vehicles where missing spot-welds are found, Toyota is developing the remedy for this condition and will notify the agency when the remedy is developed as required under 49 CFR Part 573.

 


4 Affected Products

Vehicles

MAKE MODEL YEAR
LEXUS NX250 2022
LEXUS NX350 2022
LEXUS NX350H 2022
LEXUS NX450H+ 2022

 


13 Associated Documents

April 13, 2022 DEFECT INFORMATION REPORT

RMISC-22V238-8408.pdf 130.329KB

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Recall Acknowledgement

RCAK-22V238-1544.pdf 709.3KB

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Manufacturer Notices(to Dealers,etc) – Lexus Date: April 13, 2022 SAFETY RECALL 22LA02 (Remedy Notice)

RCMN-22V238-3701.pdf 338.049KB

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Defect Notice 573 Report

RCLRPT-22V238-8744.PDF 219.312KB

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May 18, 2022 AMENDED DEFECT INFORMATION REPORT (22V238)

RMISC-22V238-5780.pdf 127.352KB

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Issued Owner Notification Letter(Part 577) – June 14, 2022

RCONL-22V238-1443.pdf 181.231KB

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Manufacturer Notices(to Dealers,etc) – Lexus DATE: 6/16/2022 TOPIC: Updated Remedy

RCMN-22V238-3402.pdf 373.498KB

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Lexus Region Letter DATE: 6/16/2022 TOPIC: Updated Remedy

RMISC-22V238-2848.pdf 292.216KB

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Recall 573 Report-Amendment 1-05/18/2022

RCLRPT-22V238-2557.PDF 219.315KB

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Recall Quarterly Report #1, 2022-2

RCLQRT-22V238-5016.PDF 211.156KB

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ISSUED Owner Notification Letter(Part 577)

RCONL-22V238-4649.pdf 403.149KB

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Recall Quarterly Report #2, 2022-3

RCLQRT-22V238-9392.PDF 211.266KB

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Recall Quarterly Report #3, 2022-4

RCLQRT-22V238-3342.PDF 211.357KB

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Latest Recalls Documents

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=22V238&docType=RCL

 


 

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