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July 12, 2023 NHTSA CAMPAIGN NUMBER: 23V478000
DC-DC Converter May Fail and Short Circuit
A short circuit can cause the DC-DC converter to overheat, increasing the risk of a vehicle fire.
NHTSA Campaign Number: 23V478
Manufacturer Toyota Motor Engineering & Manufacturing
Components ELECTRICAL SYSTEM
Potential Number of Units Affected 43,442
Summary
Toyota Motor Engineering & Manufacturing (Toyota) is recalling certain 2021-2022 RAV4 Prime and 2022 Lexus NX450h+ plug-in hybrid electric (PHEV) vehicles. The electric current rectifying module contained within the DC-DC converter may have been damaged during production, which can result in an electrical short-circuit.
Remedy
Owners are advised not to charge their vehicles when the ambient air temperature is below or expected to drop below 41 degrees Fahrenheit (5 degrees Celsius). Dealers will replace the DC-DC converter, free of charge. Owner notification letters are expected to be mailed August 7, 2023. Owners may contact Toyota’s customer service at 1-800-331-4331. Toyota’s number for this recall is 23TB07/23LB01.
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
SAFETY RECALL 23TA07 (Interim Notice 23TB07)
Certain 2021 – 2022 Model Year Rav4 Prime
Potential Risk of Vehicle Fire
Model / Years | Production Period | Approximate Total Vehicles | Approximate Stop Sale Dealer Inventory |
2021 – 2022 Model Year Rav4 Prime | Late November 2019 – Late May 2022 | 41,500 | 0 |
On July 12, 2023, Toyota filed 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 2021 – 2022 Model Year Rav4 Prime vehicles.
Condition
A component that converts electricity voltage could be damaged in manufacturing and experience a short circuit, generating excessive heat. Under certain conditions, this short circuit can generate enough heat to increase the risk of a vehicle fire.
Remedy
Toyota is currently preparing the remedy for this issue. When the remedy is available, Toyota dealers will replace the DC-DC converter with a new improved part FREE OF CHARGE. At this time, Toyota estimates the remedy can be available in the 4th quarter of 2023, but this timing is subject to change.
Covered Vehicles
There are approximately 41,500 vehicles covered by this Safety Recall. No vehicles covered by this Safety Recall were distributed to Puerto Rico.
Owner Letter Mailing Date
Toyota will notify owners by early September 2023.
Toyota 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.
New Vehicles in Dealership Inventory – Reminder
Toyota has not identified any new vehicles in dealership inventory that are covered by this Safety Recall. However, below is a reminder of the dealer’s obligations pertaining to Safety Recalls if there are new vehicles in dealership inventory:
Under Title 49, Section 30112 of the United States Code, a dealer cannot sell, offer for sale, or introduce or deliver for introduction in interstate commerce a new motor vehicle when it is aware that the vehicle does not comply with an applicable Federal Motor Vehicle Safety Standard or contains a defect related to motor vehicle safety. Further, 49 Code of Federal Regulations §577.13 requires us to provide the following advisory: It is a violation of Federal law for a dealer to deliver a new motor vehicle or any new or used item of motor vehicle equipment (including a tire) covered by this notification under a sale or lease until the defect or noncompliance is remedied.
Vehicle Safety Recall completion should always be verified through TIS. We request your assistance to ensure involved vehicles are identified and not delivered prior to performing the remedy.
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 (Non SET and GST dealers: https://dealerdaily.toyota.com/). The Vehicle Inventory Summary may take up to 4 hours to populate information for newly launched campaigns.
Pre-Owned Vehicles in Dealer Inventory
Toyota typically requests that dealers NOT deliver any pre-owned vehicles in dealer inventory that are covered by a Safety Recall unless the defect has been remedied. In this case, until remedy parts are available, delivery of a pre-owned vehicle is acceptable if disclosed to the customer that the vehicle is involved in this Safety Recall and that the remedy is currently being prepared by Toyota.
Toyota 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. Toyota 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 23TB07” 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 (Non SET and GST dealers: https://dealerdaily.toyota.com/). The Vehicle Inventory Summary may take up to 4 hours to populate information for newly launched campaigns.
Toyota Certified Used Vehicle (TCUV)
The TCUV 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 a TCUV until all applicable Safety Recalls, Special Service Campaigns, and Limited Service Campaigns have been completed on that vehicle.
Toyota Rent-A-Car (TRAC) & Service Loaners
Toyota requests that dealers remove all TRAC and 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 Toyota Brand Engagement Center (1-888-2709371) – Monday through Friday, 8:00 am to 8:00 pm, Saturday 9:00 am to 7:00 pm Eastern Time.
Head Unit Notifications
Head unit notifications are electronic messages that are displayed in the vehicle’s audio system screen. Customers who receive head unit notification regarding this Safety Recall are requested to schedule an appointment with their authorized dealer to have this Safety Recall completed.
When these messages are received by the vehicle’s Data Communication Module, the head unit will display a pop-up prompt stating that the vehicle has a new Safety Recall. The prompt will contain options to ‘Snooze’ or to ‘View’ the message. If a customer chooses ‘Snooze’, the message will continue to reappear every 20 minutes until the customer chooses ‘View’. If a customer views and then closes the message, the message will be available in the Notification App if the customer chooses to review it again. If the vehicle’s completion status remains incomplete for a period of 90 days from the message being viewed, the head unit may display a renotification pop-up prompt as an additional reminder to the customer to have this Safety Recall completed.
The message will completely clear from the vehicle once the following conditions are met: The Safety Recall is completed, the dealer has filed a claim, and the claim is approved by Toyota. Then the message will be cleared at the next clearing cycle, which currently happens daily.
Owners who receive a head unit notification after having this Safety Recall completed can be advised to ignore the message.
Owners with additional concerns can be directed to the Toyota Brand Engagement Center (1-888-270-9371) – 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 Toyota Warranty Policy 4.17, “What Is Not Covered by The Toyota 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 Joshua Burns (469) 292-6449 in Toyota Corporate Communications. Please do not provide this number to customers. Please provide this contact only to media.
Loaner Vehicle or Alternative Transportation Reimbursement Procedure
Until the vehicle is inspected and the remedy is performed, if necessary, Toyota recommends that customers refrain from charging their vehicle while the ambient temperature has been below, is below, or is expected to drop below 41 degrees Fahrenheit (5 degrees Celsius). If this is not feasible for a customer, a loaner vehicle or alternative transportation through Toyota Rent-A-CAR (TRAC) can be claimed for $42 per day.
Customer Reimbursement
Reimbursement consideration instructions will be included in the owner letter.
SAFETY RECALL 23TA07 (Interim Notice 23TB07)
Certain 2021 – 2022 Model Year Rav4 Prime Potential Risk of Vehicle Fire
Frequently Asked Questions
Original Publication Date: July 12, 2023
Q1: What is the condition?
A1: A component that converts electricity voltage could be damaged in manufacturing and experience a short circuit, generating excessive heat. Under certain conditions, this short circuit can generate enough heat to increase the risk of a vehicle fire.
Q1a: Are there any warnings when this condition occurs?
A1a: Yes, if this condition occurs on the vehicle, the hybrid vehicle control ECU may display the following warning messages :
Q1b: Is there anything I can do to prevent this issue from occurring?
A1b: Yes, until the remedy is performed, customers can reduce the potential for this condition to occur if they refrain from charging the vehicle while the ambient temperature has been below, is below, or is expected to drop below 41 degrees Fahrenheit (5 degrees Celsius ).
Q2: What is Toyota going to do?
A2: Toyota is currently preparing the remedy for this issue. When the remedy is available, Toyota dealers will replace the DC/DC converter with a new improved part FREE OF CHARGE.
Q3: When will the remedy become available?
A3: Toyota is currently preparing the parts and repair instructions for the remedy. At this time, Toyota estimates that the remedy can be available in the 4th quarter of 2023.
Q4: Which and how many vehicles are covered by this Safety Recall?
A4: There are approximately 41,500 vehicles covered by this Safety Recall.
Model Name | Model Year | Production Period |
Rav4 Prime | 2021 – 2022 | Late November 2019 – Late May 2022 |
Q4a: Are there any other Lexus/Toyota/Scion vehicles covered by this Safety Recall in the U.S.?
A4a: Yes, certain Lexus NX450h+ vehicles are also covered by this Safety Recall.
Q5: What if I previously paid for repairs related to this Safety Recall?
A5: Reimbursement consideration instructions will be provided in the owner letter.
Q6: How does Toyota obtain my mailing information?
A6: Toyota 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.
Q7: What if I have additional questions or concerns?
A7: If you have additional questions or concerns, please contact the Toyota Brand Engagement Center at 1-888-270-9371 Monday through Friday, 8:00 am to 8:00 pm, Saturday 9:00 am to 7:00 pm Eastern Time.
Description of Problem:
The plug-in hybrid system of the subject vehicles includes a DC-DC converter that reduces the voltage of the electricity from the Hybrid Vehicle (HV) battery in order to charge the vehicle’s 12V battery. Contained within the DC-DC converter is an electric current rectifying module that is installed on the circuit board. Some of these modules may have been damaged during production by the supplier and could fail. Based on its design, if the module does fail, it will not fail to an open circuit, but instead a short circuit could occur. This allows current from the 12V battery to continue to flow through the module and the module will generate heat. Under certain conditions, if excessive heat is generated, components within and outside the DC-DC converter could sustain thermal damage, increasing the risk of a vehicle fire.
Chronology of Principal Events:
June 2021 – January 2022
In mid-June 2021, Toyota received a field report from Europe which indicated the driver had observed warning messages in the display and smoke from the rear seat while driving on the highway. An initial inspection was conducted at the dealer and damage was found to be concentrated to a plastic cooling duct on the DC-DC converter located under the rear seat.
The DC-DC converter with the cooling duct was then sent to the supplier for further investigation. As a result, the supplier found the cooling duct on the DC-DC converter had melted and an electric current rectifying module inside the DC-DC converter was consumed by thermal damage. The supplier could not determine the root cause of the failure of the DC-DC converter because of the extent of damage to the DC-DC converter. Separately, an investigation including Failure Tree Analysis (FTA) at the supplier identified that semiconductor chip failure could potentially be caused by different types of manufacturing damage. At that time, it was determined that Static Electrical Charge (SEC) in the manufacturing process had the highest potential to damage the electric current rectifying module and needed further investigation.
The supplier began duplication testing with a DC-DC converter that contained a chip with damage from over voltage and/or over current which simulated the chip damaged by SEC. As a result, the supplier found that if the chip failed, a short circuit occurred and the current from the 12V battery continued to flow into the module and the module generated excessive heat, resulting in the cooling duct melting. However, Toyota confirmed the temperature around the cooling duct could not reach the ignition point of the material of the cooling duct. Toyota also confirmed that vehicle systems continue to operate as long as the 12V battery had remaining charge and that a DTC for internal short circuit of the DC-DC converter is set and the customer receives a warning message on the informational display.
February-December 2022
In mid-February, Toyota received a field report from Canada which indicated that black smoke and burned plastic smells were noticed the day after plugging a vehicle into a home charger. As a result of the inspection of the vehicle, it was confirmed the right rear seat cushion had sustained fire damage and there was melting of the cooling duct and the cooling blower adjacent the DC-DC converter. Because of the new field report, Toyota conducted further investigation to reevaluate the worst case scenario of a DC-DC converter failure. Toyota rechecked its prior analysis and reconfirmed that the highest temperature that could be reached if the DC-DC converter failed was below the ignition point of the cooling duct material, and thus would not lead to a fire.
Toyota decided to continue the investigation regarding the relationship between the failure of the DC-DC converter and the fire damage of the rear seat cushion alleged in the field report from Canada since duplication testing could not produce fire damage to the rear seat cushion material.
In late-May, the design of the rectifier module was changed so that potential damage that occurs in the manufacturing process would not cause the module to fail to a short circuit. With the design change, the module will fail to an open circuit and would not allow the flow of current from the 12V battery through the module if the module had been damaged.
In mid- June, the rear seat cushion, the DC-DC converter, and the cooling blower from the Canada vehicle were sent to Toyota to support this investigation. Toyota and the supplier investigated these parts and found that the fire did not originate from the rear seat cushion (e.g., from a cigarette or match). The module within the DC-DC converter was consumed and the cooling blower had no signs of internal heat generation. As a result, Toyota could not determine the cause of the fire damage of the rear seat alleged in the field report from Canada.
The supplier conducted multiple duplication tests with various conditions that did not include a charging condition. Under those conditions, the supplier could not duplicate the fire damage and could not identify any new information from this testing that indicated the cause of the alleged fire damage to the rear seats. Therefore, Toyota again began to review the condition of the vehicle and the recovery parts.
January 2023-July 2023
As a result of the review, Toyota determined that testing of the vehicle was needed under charging conditions. Toyota also identified the breather plug of the recovered DC-DC converter was clogged. Because of these findings, Toyota requested that the supplier begin to build a testing bench to simulate the conditions of charging with a clogged breather plug.
The supplier found that if the vehicle is charging and the HV battery temperature is low enough to require a heater be activated, the current from a sub DC-DC converter within the charger also flowed into the module, resulting in increasing the maximum temperature of the DC-DC converter. In addition, the supplier observed that if the vehicle was charging and the breather plug was clogged, the temperature in the DC-DC converter became high enough to melt the aluminum case housing the DC-DC converter. The melting created small holes within the aluminum case allowing the excessive high temperature gas inside the DC-DC converter to escape from the holes, and allowing the cooling duct to ignite.
July 6, 2023
Based on the results of the above investigation, Toyota decided to conduct a voluntary safety recall campaign.
As of June 21, 2023 based on a diligent review of records, Toyota’s best engineering judgment is that there are four Toyota Field Technical Reports and two 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.
3 Affected Products
Vehicles
MAKE | MODEL | YEAR |
LEXUS | NX450H+ | 2022 |
TOYOTA | RAV4 PRIME | 2021-2022 |
5 Associated Documents
Toyota – 23TB07 Dealer Package – July 2023
RCMN-23V478-3582.pdf 306.022KB
Defect Notice 573 Report
RCLRPT-23V478-5744.PDF 215.449KB
Recall Acknowledgement
RCAK-23V478-7262.pdf 646.025KB
Toyota – 23LB01 Dealer Package – July 2023
Toyota – Defect Information Report – July 2023
RMISC-23V478-0297.pdf 34.503KB
Latest Recalls Documents
For the Latest and Most Recent Recalls Information Visit the link below…
https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=23V478&docType=RCL
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SEOCONTENT-START
TOYOTA Toyota Motor North America, Inc. Vehicle Safety & Compliance Liaison Office Mail Stop: W4-2D 6565 Headquarters Drive Plano, TX 75024 July 12, 2023 DEFECT INFORMATION REPORT 1. Vehicle Manufacturer Name: Toyota Motor Corporation [“TMC”] 1, Toyota-cho, Toyota-city, Aichi-pref., 471-8571, Japan Affiliated U.S. Sales Company: Toyota Motor North America, Inc. [“TMNA”] 6565 Headquarters Drive, Plano, TX 75024 Manufacturer of DC-DC converter: DENSO CORPORATION 1-1, Showa-cho, Kariya-city, Aichi-pref., 448-8661, Japan Phone: +81-566-25-5511 Country of Origin: Japan 2. Identification of Involved Vehicles and Affected Components: Based on production records, we have determined the involved vehicle population as in the table below. Make/Car Line Model Year Manufacturer Production Period Toyota / RAV4 Prime 2021-2022 TMC November 25, 2019 through May 27, 2022 Lexus/ NX450h+ 2022 April 7, 2021 through May 27, 2022 Applicability Part Number Part Name Component Description MY2021-2022 Toyota RAV4 Prime G9270-42060 Converter Assy, Hybrid Vehicle DC-DC Converter MY2022 Lexus NX450h+ Note: (1) Although the involved vehicles are within the above production period range, not all vehicles in this range were sold in the U.S. (2) This issue only affects the vehicles equipped with a DC-DC converter containing a current rectifying module with the specific design described in this report. Other Toyota or Lexus vehicles sold in the U.S. are equipped with a DC-DC converter of a different design or not equipped with a DC-DC converter. 3. Total Number of Vehicles Potentially Involved: RAV4 Prime : 41,535 NX 450h+ : 1,907 Total : 43,442 4. Percentage of Vehicles Estimated to Actually Contain the Defect: Toyota is unable to estimate the percentage of the involved vehicles that actually contains the DC-DC converter with a damaged rectifying module as described in this report. However, as the NHTSA manufacturer portal requires an integer value be entered, Toyota has entered the value “1” in response to this question in the portal. For the purpose of this report, “1” means “unknown”. 5. Description of Problem: The plug-in hybrid system of the subject vehicles includes a DC-DC converter that reduces the voltage of the electricity from the Hybrid Vehicle (HV) battery in order to charge the vehicle’s 12V battery. Contained within the DC-DC converter is an electric current rectifying module that is installed on the circuit board. Some of these modules may have been damaged during production by the supplier and could fail. Based on its design, if the module does fail, it will not fail to an open circuit, but instead a short circuit could occur. This allows current from the 12V battery to continue to flow through the module and the module will generate heat. Under certain conditions, if excessive heat is generated, components within and outside the DC-DC converter could sustain thermal damage, increasing the risk of a vehicle fire. 6. Chronology of Principal Events: June 2021 – January 2022 In mid-June 2021, Toyota received a field report from Europe which indicated the driver had observed warning messages in the display and smoke from the rear seat while driving on the highway. An initial inspection was conducted at the dealer and damage was found to be concentrated to a plastic cooling duct on the DC-DC converter located under the rear seat. The DC-DC converter with the cooling duct was then sent to the supplier for further investigation. As a result, the supplier found the cooling duct on the DC-DC converter had melted and an electric current rectifying module inside the DC-DC converter was consumed by thermal damage. The supplier could not determine the root cause of the failure of the DC-DC converter because of the extent of damage to the DC-DC converter. Separately, an investigation including Failure Tree Analysis (FTA) at the supplier identified that semiconductor chip failure could potentially be caused by different types of manufacturing damage. At that time, it was determined that Static Electrical Charge (SEC) in the manufacturing process had the highest potential to damage the electric current rectifying module and needed further investigation. The supplier began duplication testing with a DC-DC converter that contained a chip with damage from over voltage and/or over current which simulated the chip damaged by SEC. As a result, the supplier found that if the chip failed, a short circuit occurred and the current from the 12V battery continued to flow into the module and the module generated excessive heat, resulting in the cooling duct melting. However, Toyota confirmed the temperature around the cooling duct could not reach the ignition point of the material of the cooling duct. Toyota also confirmed that vehicle systems continue to operate as long as the 12V battery had remaining charge and that a DTC for internal short circuit of the DC-DC converter is set and the customer receives a warning message on the informational display. February-December 2022 In mid-February, Toyota received a field report from Canada which indicated that black smoke and burned plastic smells were noticed the day after plugging a vehicle into a home charger. As a result of the inspection of the vehicle, it was confirmed the right rear seat cushion had sustained fire damage and there was melting of the cooling duct and the cooling blower adjacent the DC-DC converter. Because of the new field report, Toyota conducted further investigation to reevaluate the worst case scenario of a DC-DC converter failure. Toyota rechecked its prior analysis and reconfirmed that the highest temperature that could be reached if the DC-DC converter failed was below the ignition point of the cooling duct material, and thus would not lead to a fire. Toyota decided to continue the investigation regarding the relationship between the failure of the DC-DC converter and the fire damage of the rear seat cushion alleged in the field report from Canada since duplication testing could not produce fire damage to the rear seat cushion material. In late-May, the design of the rectifier module was changed so that potential damage that occurs in the manufacturing process would not cause the module to fail to a short circuit. With the design change, the module will fail to an open circuit and would not allow the flow of current from the 12V battery through the module if the module had been damaged. In mid- June, the rear seat cushion, the DC-DC converter, and the cooling blower from the Canada vehicle were sent to Toyota to support this investigation. Toyota and the supplier investigated these parts and found that the fire did not originate from the rear seat cushion (e.g., from a cigarette or match). The module within the DC-DC converter was consumed and the cooling blower had no signs of internal heat generation. As a result, Toyota could not determine the cause of the fire damage of the rear seat alleged in the field report from Canada. The supplier conducted multiple duplication tests with various conditions that did not include a charging condition. Under those conditions, the supplier could not duplicate the fire damage and could not identify any new information from this testing that indicated the cause of the alleged fire damage to the rear seats. Therefore, Toyota again began to review the condition of the vehicle and the recovery parts. January 2023-July 2023 As a result of the review, Toyota determined that testing of the vehicle was needed under charging conditions. Toyota also identified the breather plug of the recovered DC-DC converter was clogged. Because of these findings, Toyota requested that the supplier begin to build a testing bench to simulate the conditions of charging with a clogged breather plug. The supplier found that if the vehicle is charging and the HV battery temperature is low enough to require a heater be activated, the current from a sub DC-DC converter within the charger also flowed into the module, resulting in increasing the maximum temperature of the DC-DC converter. In addition, the supplier observed that if the vehicle was charging and the breather plug was clogged, the temperature in the DC-DC converter became high enough to melt the aluminum case housing the DC-DC converter. The melting created small holes within the aluminum case allowing the excessive high temperature gas inside the DC-DC converter to escape from the holes, and allowing the cooling duct to ignite. July 6, 2023 Based on the results of the above investigation, Toyota decided to conduct a voluntary safety recall campaign. As of June 21, 2023 based on a diligent review of records, Toyota’s best engineering judgment is that there are four Toyota Field Technical Reports and two 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. 7. Description of Corrective Repair Action: All known owners of the subject vehicles will be notified to return their vehicles to a Toyota and Lexus dealer. The dealers will replace the DC-DC converter with an improved part at no cost. Reimbursement Plan for pre-notification remedies The owner letter will instruct vehicle owners who have paid to have this condition remedied prior to this campaign to seek reimbursement pursuant to Toyota’s General Reimbursement Plan. 8. Recall Schedule: Notifications to owners of the affected vehicles will occur by September 10, 2023. A copy of the draft owner notification will be submitted as soon as it is available. 9. Distributor/Dealer Notification Schedule: Notifications to distributors/dealers will be sent on July 12, 2023. Copies of dealer communications will be submitted as they are issued. 10. Manufacturer’s Campaign Number: Interim Final Toyota: 23TB07 23TA07 Lexus: 23LB01 23LA01
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© 2023 Toyota Motor Sales, USA Toyota Motor Sales, USA, Inc. 6565 Headquarters Drive Plano, TX 75024 (469) 292-4000 Original Publication Date: July 12, 2023 To: All Toyota Dealer Principals, General Managers, Service Managers, and Parts Managers SAFETY RECALL 23TA07 (Interim Notice 23TB07) Certain 2021 – 2022 Model Year Rav4 Prime Potential Risk of Vehicle Fire Model / Years Production Period Approximate Total Vehicles Approximate Stop Sale Dealer Inventory 2021 – 2022 Model Year Rav4 Prime Late November 2019 – Late May 2022 41,500 0 On July 12, 2023, Toyota filed 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 2021 – 2022 Model Year Rav4 Prime vehicles. Condition A component that converts electricity voltage could be damaged in manufacturing and experience a short circuit, generating excessive heat. Under certain conditions, this short circuit can generate enough heat to increase the risk of a vehicle fire. Remedy Toyota is currently preparing the remedy for this issue. When the remedy is available, Toyota dealers will replace the DC-DC converter with a new improved part FREE OF CHARGE. At this time, Toyota estimates the remedy can be available in the 4th quarter of 2023, but this timing is subject to change. Covered Vehicles There are approximately 41,500 vehicles covered by this Safety Recall. No vehicles covered by this Safety Recall were distributed to Puerto Rico. Owner Letter Mailing Date Toyota will notify owners by early September 2023. Toyota 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. S a f e t y R e c a l l 2 3 T A 0 7 ( I n t e r i m 2 3 T B 0 7 ) – D – P a g e | 2 © 2023 Toyota Motor Sales, USA Dealer Inventory Procedures New Vehicles in Dealership Inventory – Reminder Toyota has not identified any new vehicles in dealership inventory that are covered by this Safety Recall. However, below is a reminder of the dealer’s obligations pertaining to Safety Recalls if there are new vehicles in dealership inventory: Under Title 49, Section 30112 of the United States Code, a dealer cannot sell, offer for sale, or introduce or deliver for introduction in interstate commerce a new motor vehicle when it is aware that the vehicle does not comply with an applicable Federal Motor Vehicle Safety Standard or contains a defect related to motor vehicle safety. Further, 49 Code of Federal Regulations §577.13 requires us to provide the following advisory: It is a violation of Federal law for a dealer to deliver a new motor vehicle or any new or used item of motor vehicle equipment (including a tire) covered by this notification under a sale or lease until the defect or noncompliance is remedied. Vehicle Safety Recall completion should always be verified through TIS. We request your assistance to ensure involved vehicles are identified and not delivered prior to performing the remedy. 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 (Non SET and GST dealers: https://dealerdaily.toyota.com/). The Vehicle Inventory Summary may take up to 4 hours to populate information for newly launched campaigns. Pre-Owned Vehicles in Dealer Inventory Toyota typically requests that dealers NOT deliver any pre-owned vehicles in dealer inventory that are covered by a Safety Recall unless the defect has been remedied. In this case, until remedy parts are available, delivery of a pre-owned vehicle is acceptable if disclosed to the customer that the vehicle is involved in this Safety Recall and that the remedy is currently being prepared by Toyota. Toyota 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. Toyota 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 23TB07” 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 (Non SET and GST dealers: https://dealerdaily.toyota.com/). The Vehicle Inventory Summary may take up to 4 hours to populate information for newly launched campaigns. Toyota Certified Used Vehicle (TCUV) The TCUV 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 a TCUV until all applicable Safety Recalls, Special Service Campaigns, and Limited Service Campaigns have been completed on that vehicle. Toyota Rent-A-Car (TRAC) & Service Loaners Toyota requests that dealers remove all TRAC and Service Loaner vehicles from service that are covered by a Safety Recall unless the defect has been remedied. S a f e t y R e c a l l 2 3 T A 0 7 ( I n t e r i m 2 3 T B 0 7 ) – D – P a g e | 3 © 2023 Toyota Motor Sales, USA Customer Handling, Parts Ordering, and Remedy Procedures 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 Toyota Brand Engagement Center (1-888-270-9371) – Monday through Friday, 8:00 am to 8:00 pm, Saturday 9:00 am to 7:00 pm Eastern Time. Head Unit Notifications Head unit notifications are electronic messages that are displayed in the vehicle’s audio system screen. Customers who receive head unit notification regarding this Safety Recall are requested to schedule an appointment with their authorized dealer to have this Safety Recall completed. When these messages are received by the vehicle’s Data Communication Module, the head unit will display a pop-up prompt stating that the vehicle has a new Safety Recall. The prompt will contain options to ‘Snooze’ or to ‘View’ the message. If a customer chooses ‘Snooze’, the message will continue to reappear every 20 minutes until the customer chooses ‘View’. If a customer views and then closes the message, the message will be available in the Notification App if the customer chooses to review it again. If the vehicle’s completion status remains incomplete for a period of 90 days from the message being viewed, the head unit may display a renotification pop-up prompt as an additional reminder to the customer to have this Safety Recall completed. The message will completely clear from the vehicle once the following conditions are met: The Safety Recall is completed, the dealer has filed a claim, and the claim is approved by Toyota. Then the message will be cleared at the next clearing cycle, which currently happens daily. Owners who receive a head unit notification after having this Safety Recall completed can be advised to ignore the message. Owners with additional concerns can be directed to the Toyota Brand Engagement Center (1-888-270-9371) – 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 Toyota Warranty Policy 4.17, “What Is Not Covered by The Toyota 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 Joshua Burns (469) 292-6449 in Toyota Corporate Communications. Please do not provide this number to customers. Please provide this contact only to media. S a f e t y R e c a l l 2 3 T A 0 7 ( I n t e r i m 2 3 T B 0 7 ) – D – P a g e | 4 © 2023 Toyota Motor Sales, USA Warranty Reimbursement Procedures Loaner Vehicle or Alternative Transportation Reimbursement Procedure Until the vehicle is inspected and the remedy is performed, if necessary, Toyota recommends that customers refrain from charging their vehicle while the ambient temperature has been below, is below, or is expected to drop below 41 degrees Fahrenheit (5 degrees Celsius). If this is not feasible for a customer, a loaner vehicle or alternative transportation through Toyota Rent-A-CAR (TRAC) can be claimed for $42 per day. Op Code Description TBD Vehicle Rental 1-30 Days TBD Vehicle Rental 31-60 Days TBD Vehicle Rental 61-90 Days TBD Vehicle Rental 91-120 Days NOTE: • Rental invoice MUST be attached to all rental claims. These claims may be subject to debit if rental invoice is not attached. • Rentals that exceed the maximum allowable daily rate will require DSPM authorization per the Toyota Transportation Assistance Policy (TTAP). • Dealers will be allowed to file these Op Codes up to 90 days after the final phase has launched into remedy. After that time, no claims for alternative transportation reimbursement will be accepted. Customer Reimbursement Reimbursement consideration instructions will be included in the owner letter. S a f e t y R e c a l l 2 3 T A 0 7 ( I n t e r i m 2 3 T B 0 7 ) – D – P a g e | 5 © 2023 Toyota Motor Sales, USA Campaign Designation / Phase Decoder 1919 = 201920 = 202021 = 202122 = 202223 = 2023Etc…Year Campaignis Launched23TA07TT = ToyotaL = LexusVehicle MakeAA = Safety Recall RemedyB = Safety Recall InterimC = Special Service CampaignD = Limited Service CampaignE = Customer Support ProgramF = Emissions Recall(May use other characters in unique cases)Field Action Category and Phase0101 = 1st Field Action of the year02 = 2nd Field Action of the year03 = 3rd Field Action of the year(The sequence is unique for each Field Action category)(May use other characters in unique cases)Field Action Sequence Examples: 19TA01 = Launched in 2019, Toyota, Safety Recall Remedy Phase, 1st Safety Recall Launched in 2019 20TC02 = Launched in 2020, Special Service Campaign, 2nd Special Service Campaign Launched in 2020 21TE05 = Launched in 2021, Customer Support Program, 5th Customer Support Program Launched in 2021 Please review this entire package with your Service and Parts staff to familiarize them with the proper step-by-step procedures required to implement this Safety Recall. Thank you for your cooperation. TOYOTA MOTOR SALES, U.S.A., INC FAQ Page 1 of 2 © 2023 Toyota Motor Sales, USA SAFETY RECALL 23TA07 (Interim Notice 23TB07) Certain 2021 – 2022 Model Year Rav4 Prime Potential Risk of Vehicle Fire Frequently Asked Questions Original Publication Date: July 12, 2023 Q1: What is the condition? A1: A component that converts electricity voltage could be damaged in manufacturing and experience a short circuit, generating excessive heat. Under certain conditions, this short circuit can generate enough heat to increase the risk of a vehicle fire. Q1a: Are there any warnings when this condition occurs? A1a: Yes, if this condition occurs on the vehicle, the hybrid vehicle control ECU may display the following warning messages : Q1b: Is there anything I can do to prevent this issue from occurring? A1b: Yes, until the remedy is performed, customers can reduce the potential for this condition to occur if they refrain from charging the vehicle while the ambient temperature has been below, is below, or is expected to drop below 41 degrees Fahrenheit (5 degrees Celsius ). Q2: What is Toyota going to do? A2: Toyota is currently preparing the remedy for this issue. When the remedy is available, Toyota dealers will replace the DC/DC converter with a new improved part FREE OF CHARGE. Q3: When will the remedy become available? A3: Toyota is currently preparing the parts and repair instructions for the remedy. At this time, Toyota estimates that the remedy can be available in the 4th quarter of 2023. FAQ Page 2 of 2 © 2023 Toyota Motor Sales, USA Q4: Which and how many vehicles are covered by this Safety Recall? A4: There are approximately 41,500 vehicles covered by this Safety Recall. Model Name Model Year Production Period Rav4 Prime 2021 – 2022 Late November 2019 – Late May 2022 Q4a: Are there any other Lexus/Toyota/Scion vehicles covered by this Safety Recall in the U.S.? A4a: Yes, certain Lexus NX450h+ vehicles are also covered by this Safety Recall. Q5: What if I previously paid for repairs related to this Safety Recall? A5: Reimbursement consideration instructions will be provided in the owner letter. Q6: How does Toyota obtain my mailing information? A6: Toyota 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. Q7: What if I have additional questions or concerns? A7: If you have additional questions or concerns, please contact the Toyota Brand Engagement Center at 1-888-270-9371 Monday through Friday, 8:00 am to 8:00 pm, Saturday 9:00 am to 7:00 pm Eastern Time. © 2023 Toyota Motor Sales, USA – Version 3a TOYOTA Toyota Motor Sales, USA, Inc. 6565 Headquarters Drive Plano, TX 75024 (469) 292-4000 CUSTOMER CONTACT & VEHICLE DISCLOSURE FORM This form is not applicable for new vehicles in dealership inventory and TCUV units. This vehicle is involved in a Safety Recall. At this time, remedy parts are not available and the remedy has NOT been performed. I understand that the vehicle will need to be returned to an authorized Toyota dealer to have the remedy performed at NO CHARGE when the remedy is available. Customer Signature Toyota recommends that you register with the Toyota Owners Community at http://www.toyota.com/owners/ and regularly check recall applicability using www.toyota.com/recall or www.safercar.gov. You will need to input your 17-digit Vehicle Identification Number (VIN). Model Model Year Customer Information Customer Name Customer Email Customer Address Home Phone # Mobile Phone # Date Please provide this information so that Toyota or your dealer can notify you when the remedy becomes available. This information will only be used for campaign communications. If you’d like to update your preferred contact information in the future, visit www.toyota.com/ownersupdate or contact us at 1-888-270-9371. Dealer Information Dealer Name/Address Dealer Code Dealer Phone Number Dealer Staff Name Dealer Staff Signature VIN Campaign Code
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OMB Control No.: 2127-0004 Part 573 Safety Recall Report 23V-478 The information contained in this report was submitted pursuant to 49 CFR §573 Manufacturer Name : Toyota Motor Engineering & Manufacturing Submission Date : JUL 12, 2023 NHTSA Recall No. : 23V-478 Manufacturer Recall No. : See attached report Manufacturer Information : Manufacturer Name : Toyota Motor Engineering & Manufacturing Address : 6565 Headquarters Drive Plano TX 75024 Company phone : 1-800-331-4331 Population : Number of potentially involved : 43,442 Estimated percentage with defect : 1 % Vehicle Information : Vehicle 1 : 2021-2022 Toyota RAV4 Prime Vehicle Type : Body Style : Power Train : NR Descriptive Information : (1) Although the involved vehicles are within the above production period range, not all vehicles in this range were sold in the U.S. (2) This issue only affects the vehicles equipped with a DC-DC converter containing a current rectifying module with the specific design described in this report. Other Toyota or Lexus vehicles sold in the U.S. are equipped with a DC-DC converter of a different design or not equipped with a DC-DC converter. Toyota is unable to estimate the percentage of the involved vehicles that actually contains the DC-DC converter with a damaged rectifying module as described in this report. However, as the NHTSA manufacturer portal requires an integer value be entered, Toyota has entered the value “1” in response to this question in the portal. For the purpose of this report, “1” means “unknown”. Production Dates : NOV 25, 2019 – MAY 27, 2022 VIN Range 1 : Begin : NR End : NR Not sequential Part 573 Safety Recall Report 23V-478 Page 2 The information contained in this report was submitted pursuant to 49 CFR §573 Vehicle 2 : 2022-2022 Lexus NX450h+ Vehicle Type : Body Style : Power Train : NR Descriptive Information : (1) Although the involved vehicles are within the above production period range, not all vehicles in this range were sold in the U.S. (2) This issue only affects the vehicles equipped with a DC-DC converter containing a current rectifying module with the specific design described in this report. Other Toyota or Lexus vehicles sold in the U.S. are equipped with a DC-DC converter of a different design or not equipped with a DC-DC converter. Toyota is unable to estimate the percentage of the involved vehicles that actually contains the DC-DC converter with a damaged rectifying module as described in this report. However, as the NHTSA manufacturer portal requires an integer value be entered, Toyota has entered the value “1” in response to this question in the portal. For the purpose of this report, “1” means “unknown”. Production Dates : APR 07, 2021 – MAY 27, 2022 VIN Range 1 : Begin : NR End : NR Not sequential Description of Defect : Description of the Defect : The plug-in hybrid system of the subject vehicles includes a DC-DC converter that reduces the voltage of the electricity from the Hybrid Vehicle (HV) battery in order to charge the vehicle’s 12V battery. Contained within the DC-DC converter is an electric current rectifying module that is installed on the circuit board. Some of these modules may have been damaged during production by the supplier and could fail. Based on its design, if the module does fail, it will not fail to an open circuit, but instead a short circuit could occur. This allows current from the 12V battery to continue to flow through the module and the module will generate heat. Under certain conditions, if excessive heat is generated, components within and outside the DC-DC converter could sustain thermal damage, increasing the risk of a vehicle fire. FMVSS 1 : NR FMVSS 2 : NR Description of the Safety Risk : Under certain conditions, if excessive heat is generated, components within and outside the DC-DC converter could sustain thermal damage, increasing the risk of a vehicle fire. Description of the Cause : NR Identification of Any Warning that can Occur : NR Involved Components : Part 573 Safety Recall Report 23V-478 Page 3 The information contained in this report was submitted pursuant to 49 CFR §573 Component Name 1 : Converter Assy, Hybrid Vehicle Component Description : DC-DC Converter Component Part Number : G9270-42060 Supplier Identification : Component Manufacturer Name : Denso Corporation Address : 1-1, Showa-cho, Kariya-city Aichi-pref. Foreign States 448-8661 Country : Japan Chronology : Please see the attached Part 573 Defect Information Report for the full chronology. Description of Remedy : Description of Remedy Program : All known owners of the subject vehicles will be notified to return their vehicles to a Toyota and Lexus dealer. The dealers will replace the DC-DC converter with an improved part at no cost. The owner letter will instruct vehicle owners who have paid to have this condition remedied prior to this campaign to seek reimbursement pursuant to Toyota’s General Reimbursement Plan. How Remedy Component Differs from Recalled Component : NR Identify How/When Recall Condition was Corrected in Production : NR Recall Schedule : Description of Recall Schedule : Notifications to owners of the affected vehicles will occur by September 10, 2023. A copy of the draft owner notification will be submitted as soon as it is available. Part 573 Safety Recall Report 23V-478 Page 4 The information contained in this report was submitted pursuant to 49 CFR §573 Notifications to distributors/dealers will be sent on July 12, 2023. Copies of dealer communications will be submitted as they are issued. Planned Dealer Notification Date : JUL 12, 2023 – JUL 12, 2023 Planned Owner Notification Date : AUG 07, 2023 – SEP 10, 2023 * NR – Not Reported
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