23TA09 – Increased Risk of Fire – 2022-2023 Toyota Tundra & Tundra Hybrid

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August 10, 2023 NHTSA CAMPAIGN NUMBER: 23V566000

Fuel Leak from Damaged Fuel Tube

A fuel leak in the presence of an ignition source can increase the risk of a fire.

 

NHTSA Campaign Number: 23V566

Manufacturer ToyotaeBay Motor Engineering & Manufacturing

Components FUEL SYSTEM, GASOLINE

Potential Number of Units Affected 168,179

 

Summary

ToyotaeBay Motor Engineering & Manufacturing (ToyotaeBay) is recalling certain 2022-2023 Tundra and Tundra Hybrid vehicles. The plastic fuel tube routed near metallic brake lines may chafe against the brake lines and become damaged, possibly resulting in a fuel leak.

 

Remedy

As an interim repair, dealers will install protective materials and a clamp on the fuel tube, free of charge. Once the final remedy is available, dealers will replace the fuel tube, free of charge. Owner notification letters are expected to be mailed September 25, 2023. Owners may contact ToyotaeBay’s customer service at 1-800-331-4331. ToyotaeBay’s numbers for this recall are 23TB09/23TA09.

 

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

 


August 10, 2023

SAFETY RECALL 23TA09 (Interim Notice 23TB09)

Certain 2022 – 2023 Model Year Tundra HV Vehicles
Certain 2022 – 2023 Model Year Tundra Vehicles  Increased Risk of Fire

 

Model / Years Production Period Approximate Total VehiclesApproximate Stop Sale Dealer Inventory
2022 – 2023 Model year Tundra  Early November 2021 – Late July 2023138,400400
2022 – 2023 Model year Tundra HVMid March 2022 – Early June 202329,800200

 

STOP! DO NOT SELL NEW VEHICLES IN DEALER INVENTORY.

Refer to Dealer Inventory Procedures section for more details.

 

On August 10, 2023, ToyotaeBay 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 certain 2022-2023 model year Tundra HV and certain 2022-2023 model year Tundra vehicles.

 

Condition

The subject vehicles are equipped with a plastic fuel tube which could move and rub against a brake line and develop a fuel leak.  A fuel leak in the presence of an ignition source could increase the risk of fire.

 

Remedy

For all involved vehicles, ToyotaeBay dealers will replace the fuel tube with an improved part and additional clamps FREE OF CHARGE to customers.  ToyotaeBay is currently preparing the remedy parts for this recall.  As a temporary measure until final remedy parts are available, the dealers will install protective materials and a clamp on the fuel tube FREE OF CHARGE. At this time, ToyotaeBay expects the temporary measure will be available in October 2023.

 

Covered Vehicles

There are approximately 168,200 vehicles covered by this Safety Recall. Approximately 1,600 vehicles involved in this Safety Recall were distributed to Puerto Rico.

 

Owner Letter Mailing Date

ToyotaeBay will notify owners by early October 2023.

ToyotaeBay 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.

 

Dealer Inventory Procedures

New Vehicles in Dealership Inventory 

There are approximately 600 vehicles in new dealer inventory as of August 8, 2023.

 

Inspection Reminder Mirror Hang Tags for Covered Vehicles in New Dealer Stock

To easily recognize vehicles involved in this Safety Recall, each dealership should utilize Inspection Reminder Hang Tags. Inside the vehicle’s glove box are stickers containing the VIN. Apply one of these stickers to the hang tag and install the hang tag in the vehicle. A sample copy of the Inspection Reminder Hang Tag has been included for your reference. ToyotaeBay Version Below

 

Pre-Owned Vehicles in Dealer Inventory

ToyotaeBay 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 ToyotaeBay.

ToyotaeBay 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. ToyotaeBay 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@toyotaeBay.com. In the subject line of the email, state “Disclosure Form 23TB09” 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

ToyotaeBay 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 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 ToyotaeBay 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.

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 ToyotaeBay. 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 ToyotaeBay 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 ToyotaeBay Warranty Policy 4.17, “What Is Not Covered by The ToyotaeBay 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 ToyotaeBay Corporate Communications. Please do not provide this number to customers. Please provide this contact only to media.

 

Customer Reimbursement

Reimbursement consideration instructions will be included in the owner letter.

 


Frequently Asked Questions
Original Publication Date: August 10, 2023

 

Q1: What is the condition?

A1: The subject vehicles are equipped with a plastic fuel tube which could move and rub against a brake line and develop a fuel leak.  A fuel leak in the presence of an ignition source could increase the risk of fire.

 

Q1a: Are there any symptoms or warnings that this condition exists?

A1a: A fuel smell while driving and/or parked may be noticed.  Leaking fuel may also be seen near the right rear wheel area of the vehicle.

 

Q2: What is ToyotaeBay going to do?

A2: For all involved vehicles, ToyotaeBay dealers will replace the fuel tube with an improved part and additional clamps FREE OF CHARGE to customers.  ToyotaeBay is currently preparing the remedy parts for this recall.  As a temporary measure until final remedy parts are available, the dealers will install protective materials and a clamp on the fuel tube FREE OF CHARGE. At this time, ToyotaeBay expects the temporary measure will be available in October 2023.

 

Q3: When will the remedy become available?

A3:ToyotaeBay is currently preparing the remedy for this issue.  At this time, ToyotaeBay expects the temporary measure will be available in October 2023.

 

Q4: Which and how many vehicles are covered by this Safety Recall?

A4: There are approximately 168,200 vehicles covered by this Safety Recall.

Model Name Model Year Production Period
Tundra2022-2023Early November 2021 – Late July 2023
Tundra HV2022-2023Mid March 2022 – Early June 2023

 

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 ToyotaeBay obtain my mailing information?

A6: ToyotaeBay 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 ToyotaeBay 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.

 


Percentage of Vehicles Estimated to Actually Contain the Defect:
ToyotaeBay is unable to estimate the percentage of the involved vehicles that actually will develop a fuel leak, as this depends on how a vehicle is assembled and the conditions under which it is operated. However, as the NHTSA manufacturer portal requires an integer value be entered, ToyotaeBay has entered the value “1” in response to this question in the portal. For the purpose of this report, “1” means “unknown”.

 

Description of Problem:
The subject vehicles are equipped with a plastic fuel tube that is held in place by a clamp and routed near metallic brake lines at the top of the fuel tank. The clamp can allow the fuel tube to move into contact with the adjacent brake line under certain driving conditions. Over time, driving and other induced vibrations can cause the fuel tube to rub against the brake line, which could result in a fuel leak if the fuel tube wall wears through. A fuel smell while driving and or while parked may be noted; leaking fuel may also be observed near the right rear wheel area of the vehicle. A fuel leak in the presence of an ignition source could increase the risk of fire.

 

Chronology of Principal Events:

November 2022 – December 2022
In November 2022, ToyotaeBay received a dealer report indicating the customer’s vehicle was leaking fuel from the fuel tube on top of the fuel tank assembly. The report indicated that the fuel tube appears to have been making contact with the frame rail. The fuel tube was recovered for investigation.

January 2023-July 2023
In late January, ToyotaeBay received an additional report, documenting a ToyotaeBay field staff’s conversation with a dealer technician, indicating a customer’s vehicle was leaking fuel near the fuel tank. As this vehicle had been repaired and no longer available for inspection, the ToyotaeBay field staff inspected two like model Tundra vehicles and noted that the fuel tube could be moved by hand and that, when moved, it could come in contact with the near-by brake line located on the frame rail. One of the two Tundra vehicles was also found to have possible contact with the brake line along the frame rail. The leaking fuel tube from the repaired vehicle noted in the field report was recovered for additional investigation.

In February, ToyotaeBay inspected the two fuel tubes noted above and found the fuel tube wall was worn through on those parts. However, it could not be determined how the fuel tube had contacted other vehicle parts, as noted in the reports, and if that contact resulted in the fuel tube leaking. ToyotaeBay began inspecting company fleet vehicles and found visible signs of fuel tube movement from its original installed position towards the brake line. During this time, the manufacturing plant implemented an in-line inspection to confirm that there was no contact between the fuel tube and brake line and that components were being assembled correctly. The manufacturing plant also surveyed vehicles in the yard and did not identify any with contact between the fuel tube and brake line.

Based on initial investigation activities, it could not be determined how the fuel tube may have contacted surrounding parts. Therefore, ToyotaeBay began vehicle dynamic tests to evaluate any potential movement of the fuel tube while driving; it observed that the fuel tube moved towards and contacted the brake line. Additionally, ToyotaeBay ran cycle tests, based on ToyotaeBay internal standards, on fuel tubes to understand if the contact observed on the aforementioned vehicles could wear through the fuel tube wall, resulting in a leak. A leak condition could not be duplicated during these standard tests. ToyotaeBay ran additional tests under more severe conditions than the standard tests, which included artificially positioning components so that there would be high contact force between the fuel tube and brake line. This testing could create wear through the fuel tube wall; however, the resulting amount of wear on the fuel tube was much greater than observed on vehicles in the market.

ToyotaeBay visited the fuel tube supplier to understand the investigation results from other recovered fuel tubes, as well as to audit the current fuel tube manufacturing process. During this audit, new and recovered fuel tubes were inspected on a check fixture, and it was found that the shape of the fuel tubes was out of specification. Modified fuel tube tooling and procedures to bring the fuel tube back into specification began to be developed.

Based on the observations of fuel tube contact to surrounding components from dynamic testing and findings from the supplier of the fuel tube shape being out of specification, ToyotaeBay began investigating the design and tolerance stack-up of the fuel tube in relation to its surrounding components. Through this engineering analysis, ToyotaeBay found that the design and worst-case tolerance stack-up of the fuel tube and surrounding components could result in fuel tube migration and then contact with a near-by brake line, which could result in a fuel leak.

ToyotaeBay also conducted a field survey to see if vehicles in the field had a contact condition between the fuel tube and brake line. Of the vehicles surveyed, ToyotaeBay found that more than half of the vehicles had a contact condition, with one having a fuel leak.

ToyotaeBay conducted various testing activities, including spray pattern and rate tests, to assess the potential effect of the fuel leak. It was determined that the leaking fuel would likely not contact potential ignition sources on the vehicle. However, ToyotaeBay evaluated the potential fuel leak condition on a vehicle parked and running for extended periods of time. Based on this evaluation, ToyotaeBay determined this condition could increase of the risk of a fire in the presence of an external ignition source.

August 7, 2023
Based on the results of the above investigation, ToyotaeBay decided to conduct a voluntary safety recall campaign.
As of August 7, 2023, based on a diligent review of records, ToyotaeBay’s best engineering judgment is that there are fourteen ToyotaeBay Field Technical Reports and twenty-seven 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 ToyotaeBay dealer. The dealers will replace the fuel tube with an improved part and additional clamps at no cost to customers. ToyotaeBay is currently preparing the remedy parts for this recall. As a temporary measure until final remedy parts are available, the dealers will install protective materials and a clamp on the fuel tube at no cost to customers.

 


4 Affected Products

Vehicles

MAKEMODELYEAR
TOYOTAeBayTUNDRA2022-2023
TOYOTAeBayTUNDRA HYBRID2022-2023

 


4 Associated Documents

Defect Notice 573 Report

RCLRPT-23V566-8199.PDF 215.648KB

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ToyotaeBay – 23TB09 Dealer Packet – August 2023

RCMN-23V566-3880.pdf 328.27KB

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ToyotaeBay – Notice of Defect – August 2023

RMISC-23V566-8490.pdf 131.064KB

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Recall Acknowledgement

RCAK-23V566-5157.pdf 645.977KB

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Bestseller No. 8
ANCEL AD610 Pro ABS SRS OBD2 Scanner, ABS Bleeding, SAS Calibration, ABS, Airbag, EPB, Oil Reset, Full OBD2 Functions, AutoVIN, Free Lifetime WiFi Updates
  • All New AD610 Pro - This remarkable tool has entirely new technology. Unlike other OBD2 scanners that merely support USB upgrades on PC and demand registration, ours offers WiFi updates without any registration requirements, thus saving 90% of the time it takes. Additionally, the operating speed of our new software has increased by 30% and the vehicles' compatibility has risen by 20%. The compatibility depends year and model, please inform VIN for compatible check.
  • ABS Diagnosis & Reset - Effectively read and clear ABS error codes or reset ABS-related sensors after repairs. Addresses issues such as front or rear wheel speed sensor failure, sensor voltage irregularities, steering angle sensor faults, yaw rate, or G sensor malfunctions. Ensure safe driving with reliable system performance.
  • SRS Diagnosis & Reset - Read and clear SRS error codes or reset SRS-related sensors after repairs. Resolves issues like crash data recorded on the driver side (airbag replacement required), occupant classification system defects, or seat track position sensor malfunctions. Helps avoid airbag failure in an accident.
  • Optimal ABS Bleed, Smooth Braking - When there's air in the ABS, it affects braking performance. Our tool helps auto bleed the brake system by purging the air, ensuring no air bubbles in the brake lines, for proper operation and optimal performance. This maintenance task is typically done when replacing brake fluid or servicing brake components, to ensure braking system stability and reliability. Note: this feature is not compatible with vehicles that only support manual bleeding.
  • SAS Calibration Essential - Enjoy precision steering and enhanced safety through our SAS calibration feature. By ensuring accurate alignment of your vehicle's steering angle sensor (SAS), SAS calibration delivers precise control, eliminates steering drift, and prevents uneven tire wear. Improve handling and maneuverability on the road, even in challenging conditions, while driving with confidence knowing that your steering system is finely tuned for maximum performance and safety.
Bestseller No. 9
OBD2 Scanner TOPDON AD500, Oil SAS Throttle TPMS BMS EPB Reset, Engine ABS SRS Transmission, Diagnostic Scan Tool, AutoVIN, Car Check Engine Code Reader with Battery Test, Lifetime Wi-Fi Free Update
  • [Brand-New ArtiDiag500] We've got everything you're looking for! Forget basic OBD2 scanners; TOPDON's ArtiDiag500 car scanner offers more. The all-new ArtiDiag500 not only includes full OBD2 functions and 4-system diagnostics but also provides DIYers with 6 maintenance services. The brand-new, cost effective AD500 is back in full swing!
  • [4-System Diagnostics] DIY enthusiasts, take notice! Will these 4-system diagnostics be the treasure you've been seeking? The ArtiDiag500 code reader offers in-depth testing for the engine, transmission, ABS, and SRS systems, reading fault codes and data streams. It also visualizes real-time data in chart form, simplifying complex data for storage and future playback, aiding DIY users in problem detection.
  • [6 Reset Functions] Hey, hang tight for a moment. With these 6 reset functions, the ArtiDiag500 has got you covered. It offers throttle adaptation along with reset capabilities for Oil, SAS, TPMS, BMS, and EPB. Seamlessly aligning the throttle, battery, tires, and brake pads with your vehicle, it also adjusts the steering angle and turns off the oil light. Looking to restore your car to its original condition? Look no further than the ArtiDiag500.
  • [Multiple Functions] The Smart AutoVIN of this TOPDON OBD2 scanner keeps track of your manual selections for vehicle make, model, and year and directs you to the suitable diagnostics. Max 4 Live Data streams integrated for much easier data processing. Diagnostic feedback online with this diagnostic tool to help you get tough repair operations well-completed. Real-time car battery voltage monitoring identifies probable vehicle defects.
  • [Global Support] Rest assured about compatibility with your vehicle and language – ArtiDiag500 currently supports 67+ car brands, 10,000+ models, covering most vehicles worldwide, and is available in 12 languages. Whether it's for your car or preferred language, there's an ideal choice for you. Plus, it's fully compatible with Android 11 for smoother use.
Bestseller No. 10
Innova 1000 OBD2 Scanner Bluetooth for iPhone & Android Compatible with America’s Top Car Repair App - No Subscription Fee - OBDII Scan Tool and Code Reader to Diagnose Check Engine, ABS, SRS
  • Bluetooth OBD2 Scanner for Diagnostics – The Innova 1000 connects to compatible devices via Bluetooth, allowing you to view data from engine, ABS, SRS, transmission, and more. For accurate readings and trouble code information, check compatibility with Innova’s Coverage Checker before purchase.
  • Portable and User-Friendly Design – This car scanner is lightweight and easy to use, making it a practical portable scanner for home garages and roadside use. Suitable for both DIYers and professionals, it offers reliable performance for everyday diagnostics.
  • Compatible with Most Vehicles (1996 & Newer) – Supports most cars, trucks, and SUVs from brands like Toyota, Ford, HondaeBay, Chevrolet, Nissan, and more. Compatibility may vary by vehicle. Use Innova’s Coverage Checker to verify before purchase.
  • No Subscriptions or Hidden Fees – Our wireless OBD2 scanner provides access to verified fixes and diagnostic solutions without subscription costs. Use America’s Top Car Repair App, RepairSolutions2, to receive repair guidance, part recommendations, and cost estimates with no additional charges. Join 2.6 million app users.
  • Accurate Code Reading and Real-Time Data – This car diagnostic scanner delivers real-time data, including engine performance, ABS, SRS, and transmission codes. Ideal for checking engine light issues and preparing for emissions tests.

 


Last update on 2025-04-17 / Affiliate links / Images from Amazon Product Advertising API


 

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