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 Toyota Motor Engineering & Manufacturing

Components FUEL SYSTEM, GASOLINE

Potential Number of Units Affected 168,179

 

Summary

Toyota Motor Engineering & Manufacturing (Toyota) 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 Toyota’s customer service at 1-800-331-4331. Toyota’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 Vehicles Approximate Stop Sale Dealer Inventory
2022 – 2023 Model year Tundra   Early November 2021 – Late July 2023 138,400 400
2022 – 2023 Model year Tundra HV Mid March 2022 – Early June 2023 29,800 200

 

STOP! DO NOT SELL NEW VEHICLES IN DEALER INVENTORY.

Refer to Dealer Inventory Procedures section for more details.

 

On August 10, 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 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, Toyota dealers will replace the fuel tube with an improved part and additional clamps FREE OF CHARGE to customers.  Toyota 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, Toyota 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

Toyota will notify owners by early October 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.

 

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. Toyota Version Below

 

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 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

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 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 (1-888-2709371) – 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 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.

 

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 Toyota going to do?

A2: For all involved vehicles, Toyota dealers will replace the fuel tube with an improved part and additional clamps FREE OF CHARGE to customers.  Toyota 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, Toyota expects the temporary measure will be available in October 2023.

 

Q3: When will the remedy become available?

A3:Toyota is currently preparing the remedy for this issue.  At this time, Toyota 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
Tundra 2022-2023 Early November 2021 – Late July 2023
Tundra HV 2022-2023 Mid 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 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.

 


Percentage of Vehicles Estimated to Actually Contain the Defect:
Toyota 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, Toyota 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, Toyota 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, Toyota received an additional report, documenting a Toyota 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 Toyota 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, Toyota 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. Toyota 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, Toyota 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, Toyota ran cycle tests, based on Toyota 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. Toyota 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.

Toyota 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, Toyota began investigating the design and tolerance stack-up of the fuel tube in relation to its surrounding components. Through this engineering analysis, Toyota 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.

Toyota 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, Toyota found that more than half of the vehicles had a contact condition, with one having a fuel leak.

Toyota 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, Toyota evaluated the potential fuel leak condition on a vehicle parked and running for extended periods of time. Based on this evaluation, Toyota 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, Toyota decided to conduct a voluntary safety recall campaign.
As of August 7, 2023, based on a diligent review of records, Toyota’s best engineering judgment is that there are fourteen Toyota 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 Toyota dealer. The dealers will replace the fuel tube with an improved part and additional clamps at no cost to customers. Toyota 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

MAKE MODEL YEAR
TOYOTA TUNDRA 2022-2023
TOYOTA TUNDRA HYBRID 2022-2023

 


4 Associated Documents

Defect Notice 573 Report

RCLRPT-23V566-8199.PDF 215.648KB

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Toyota – 23TB09 Dealer Packet – August 2023

RCMN-23V566-3880.pdf 328.27KB

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Toyota – 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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Latest Recalls Documents

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=23V566&docType=RCL

 


 

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ABS SRS Transmission Airbag Car Scanner, Check Engine Car Code Reader, Automotive Scan Tool for All Cars" rel="nofollow noopener sponsored" target="_blank"> ANCEL FX2000 OBD2 Scanner Diagnostic Tool, ABS SRS Transmission Airbag Car Scanner, Check Engine Car Code Reader, Automotive Scan Tool for All Cars
ANCEL FX2000 OBD2 Scanner Diagnostic Tool, ABS SRS Transmission Airbag Car Scanner, Check Engine Car Code Reader, Automotive Scan Tool for All Cars
  • 💻Note: (About UPDATE) ANCEL FX2000 car scanner diasgnostic tool can be used directly as it comes with existed software, You don't need to register or update beforethe first use. It's recommended to update your scanner only when it fails to work on your car, or it's slow to load all menus or if you need newer software version. 📢Software update supports WIN XP, 7, 8, 10 operation systems only., but not for Mac and ios system.
  • 🔧【PLUG AND PLAY - EASY TO USE】 : ANCEL FX2000 car scanner only takes 3 steps to connect to the car for diagnosis without cumbersome operations. The latest FX2000 scan tool is equipped with a one-key diagnosis function, which can automatically identify the model and year of your car, and automatically diagnose the car. Even beginners can use it to read the data and find out what the fault codes mean.
  • 🚗【FULL OBD-LEVEL DIAGNOSTICS TOOL】: Quickly determines the cause of engine system faults, reads current, permanent and pending codes. After the repair, clears the codes and turns off the warning light. In addition, the FX2000 engine code reader also displays important OBD II advanced data such as fuel, live data and other manufacturer-specific parameters in real time to ensure that the engine ECU is operating correctly and safely, saving vehicle owners a lot of time and money in maintenance.
  • 🚙【TRANSMISSION FAULT DIAGNOSTIC TOOL】: Some noises come from the transmission? Ancel obd2 scanner will read fault codes, display live transmission system data (fluid temperature, fluid pump, clutch actuation, pressure, etc.), and ensures transmission performance is optimal for vehicle speed and load. It provides detailed TCM data of the vehicle, so you can quickly and accurately find existing or potential problems.
  • 🚐【FIND OUT SRS WRONG】: ANCEL FX2000 automotive scanner is able to read and clear fault codes in the SRS (airbag) and turn off the warning light to make sure the system is working correctly and safely. This odb2 scanner also displays a live graphical data stream of the supplemental restraint system (air bag), which allows you to analyze and verify that the air bag system is working properly.
SaleBestseller No. 9
OBD2 Scanner TOPDON AL600, ABS SRS Code Reader, Diagnostic Scan Tool, Active Test for ABS/SRS, with Car Maintenance Reset Service of Oil, BMS, SAS
  • ABS/SRS OBD2 Scanner > Enjoy this ABS OBD2 code reader to reveal exact issues underlying in your brake, airbag, and engine systems, test individual ABS/SRS sensors, valves, or solenoids to quickly locate malfunctions (compatible with GM, Nissan, Fiat, Benz, Volvo, Land Rover, BMW, USA Ford, please reach us for details.), making sure critical safety systems work in perfect harmony together against accidents to be safe than sorry. NOTE: Only support upgrade on windows.
  • 3 Most Needed Service Functions > This OBD2 scanner guides you through step by step procedures to reset oil service light and programmed mileage intervals for engine efficiency (Oil Reset); to calibrate steering wheel position for vehicle’s traveling in a straight line (SAS Reset); to clear the original low battery fault information against coming battery failures or damage (BMS Reset); saving your needless visits to mechanics. NOTE: Not suitable for all models, please reach us for compatibility.
  • Full OBD2 Diagnostics > Say goodbye to the hassle of manual check-ups via this srs code reader. Quickly correct Check Engine Light warning on most OBD2/CAN compatible vehicles. Easily access to your smog status with one simple click I/M Readiness; and being filled with features for live data readings, freeze frame data, plus EVAP system, onboard monitor test means this scan tool checks all daily car care boxes.
  • Work Easier > Red-Yellow-Green LEDs in this OBD2 scanner quickly show the overall DTC status without toggling through menu selections. HELP hotkey takes you directly to detailed descriptions/tips. Read/Erase DTC, I/M readiness shortcuts are added for optimized operation, along with DTC Lookup library for interpreting codes, designing the SRS OBD2 code reader a pleasure to use right out of the package even for beginners.
  • Helpful Service > Get instant, free lifetime access to the most recent updates to add new car models and troubleshooting bugs making the OBD2 scanner a long-term investment for any home mechanics. The extended 1 years of quality assurance sweetens the worry-free deal even further. Multilingual Menu: EN, FR, ES, DE, IT, RU, PT, and JP. NOTE: Only support upgrade on windows.
SaleBestseller No. 10
ANCEL VD500 OBD II Diagnostic Scanner for Volkswagen VW Audi Skoda Seat Diagnosis Check Engine Light EPB ABS SRS Code Reader Oil Throttle Position Adaption Brake Pad Reset Tool
  • The VD500 OBD2 scanner is specifically designed to diagnose Volkswagen Group (Fits for VW/Audi/Skoda/ SEAT) 12-volt 16-pin vehicles, but can also be used with other 12-volt (non-Volkswagen) and light trucks (non-electric) vehicles manufactured in 1996 or later that are OBD II -compliant with standard 16-pin OBD II protocols (J1850 VPM, J1850PWM, ISO9141, KWP 2000 and CAN).
  • For Volkswagen (VAG) vehicles diagnostics, the device can not only read and clear codes on engine, ABS, transmission, SAS (not all cars), ESP, TPMS and other systems, but also reset the oil, brake pad and throttle position adaption.
  • For other OBD II vehicles (non-Volkswagen), the VD500 can read and clear fault codes, display fault code definitions, turn off the CEL (check engine light) and retrieve VIN information ONLY.
  • The VD500 diagnostic offering for Volkswagen vehicles covers the following vehicles: fits for VW (CC, EOS, Golf, GTI, Jetta, Passat, Phaeton, Polo, Rabbit, Sharan, Tiguan, Touran, Touareg); fits for Audi (A3, A4, A6, A7, A8, A5, Q3, Q5, Q7, R8, RS3, TT, RS, RS5, S4, S6); fits for Skoda (Octavia, Rapid, Yeti, Kodiaq, Fabio, Superb); fits for SEAT (Leon, Ateca, Ibiza, Altea, Cushion, Cord, Alhambra) Diagnostics.
  • With English and German as display languages, this diagnostic tool provides life-time free software updates to fix the latest bugs or add new parameters. Simply download the software from the official website, then follow on-screen instructions to install it.

Last update on 2024-04-21 / Affiliate links / Images from Amazon Product Advertising API

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