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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
Toyota – 23TB09 Dealer Packet – August 2023
Toyota – Notice of Defect – August 2023
RMISC-23V566-8490.pdf 131.064KB
Recall Acknowledgement
RCAK-23V566-5157.pdf 645.977KB
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=23V566&docType=RCL
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- 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.
- 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
This product presentation was made with AAWP plugin.
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TOYOTA Toyota Motor North America, Inc. Vehicle Safety & Compliance Liaison Office Mail Stop: W4-2D 6565 Headquarters Drive Plano, TX 75024 August 10, 2023 DEFECT INFORMATION REPORT 1. Vehicle Manufacturer Name: Toyota Motor Manufacturing, Texas, Inc. [“TMMTX”] 1 Lone Star Pass, San Antonio, TX 78264-3413 Affiliated U.S. Sales Company: Toyota Motor North America, Inc. [“TMNA”] 6565 Headquarters Drive, Plano, TX 75024 Manufacturer of Fuel Tank Assembly: Textron Inc. (Corporate) 40 Westminster Street Providence, RI 02903 Phone: +1-401-421-2800 Country of Origin: USA 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 / Tundra 2022-2023 TMMTX November 2, 2021 through July 24, 2023 Toyota / Tundra Hybrid March 15, 2022 through June 7, 2023 Applicability Part Number Part Name Component Description MY2022-2023 Toyota Tundra/ Tundra Hybrid 77209-0C180 Tube Sub-Assy. Fuel Tank Main Fuel Tube Assembly 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 certain Tundra and Tundra Hybrid vehicles equipped with a fuel tube assembly and surrounding components of a specific design prior to production changes to protect and secure the fuel tube. Other Toyota or Lexus vehicles sold in the U.S. are not equipped with a fuel tube and surrounding components of this design and are not affected by the condition described in Section 5 below. 3. Total Number of Vehicles Potentially Involved: Tundra : 138,410 Tundra Hybrid : 29,769 Total : 168,179 4. 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”. 5. 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. 6. 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. 7. 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. 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 October 9, 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 August 10, 2023. Copies of dealer communications will be submitted as they are issued. 10. Manufacturer’s Campaign Number: [Interim / Remedy] 23TB09 / 23TA09
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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: August 10, 2023 To: All Toyota Dealer Principals, General Managers, Service Managers, and Parts Managers 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. S a f e t y R e c a l l 2 3 T A 0 9 ( I n t e r i m 2 3 T B 0 9 ) – P a g e | 2 © 2023 Toyota Motor Sales, USA Dealer Inventory Procedures New Vehicles in Dealership Inventory There are approximately 600 vehicles in new dealer inventory as of August 8, 2023. 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. Toyota reimburses dealers for flooring costs associated with new vehicles held in dealership inventory until the recall remedy becomes available. Toyota provides these flooring reimbursements at 60-day intervals. Toyota reserves the right to withhold or charge-back any flooring reimbursement funds that may have been paid to the dealer if it determines that a new vehicle subject to a safety recall was sold without first being 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: • New vehicles in dealer inventory subject to a Safety Recall must be remedied before delivery into commerce under a sale or lease. Dealer-to-dealer trades as well as vehicle sales between dealers should not be made until a vehicle is remedied. • 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. S a f e t y R e c a l l 2 3 T A 0 9 ( I n t e r i m 2 3 T B 0 9 ) – P a g e | 3 © 2023 Toyota Motor Sales, USA 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. NOTE: Dealerships can order hang tags from the Material Distribution Center (MDC). Part Number Description Quantity 00411-140003 Inspection Mirror Hang Tag 25 Per Pack S a f e t y R e c a l l 2 3 T A 0 9 ( I n t e r i m 2 3 T B 0 9 ) – P a g e | 4 © 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. 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 9 ( I n t e r i m 2 3 T B 0 9 ) – P a g e | 5 © 2023 Toyota Motor Sales, USA Warranty Reimbursement Procedures Loaner Vehicle or Alternative Transportation Reimbursement Procedure If the vehicle owner is uncomfortable driving their vehicle while we prepare the temporary remedy, a loaner vehicle or alternative transportation through Toyota Rent-A-CAR (TRAC) can be claimed for $55 per day. Op Code Description TBD Vehicle Rental 1-30 Days TBD Vehicle Rental 31-60 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 9 ( I n t e r i m 2 3 T B 0 9 ) – P a g e | 6 © 2023 Toyota Motor Sales, USA Campaign Designation / Phase Decoder 23 19 = 2019 20 = 2020 21 = 2021 22 = 2022 23 = 2023 Etc… Year Campaign is Launched 23TB09 T T = Toyota L = Lexus Vehicle Make B A = Safety Recall Remedy B = Safety Recall Interim C = Special Service Campaign D = Limited Service Campaign E = Customer Support Program F = Emissions Recall (May use other characters in unique cases) Field Action Category and Phase 09 01 = 1st Field Action of the year 02 = 2nd Field Action of the year 03 = 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 23TA09 (Interim Notice 23TB09) Certain 2022-2023 Model Year Tundra HV Vehicles Certain 2022 – 2023 Model Year Tundra Vehicles Increased Risk of Fire Frequently Asked Questions Original Publication Date: August 10, 2023 ◄ IMPORTANT UPDATE ► DATE TOPIC 8/11/2023 Temporary repair timing update The most recent update will be highlighted with a red box. 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. FAQ Page 2 of 2 © 2023 Toyota Motor Sales, USA 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 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-566 The information contained in this report was submitted pursuant to 49 CFR §573 Manufacturer Name : Toyota Motor Engineering & Manufacturing Submission Date : AUG 10, 2023 NHTSA Recall No. : 23V-566 Manufacturer Recall No. : 23TB09 / 23TA09 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 : 168,179 Estimated percentage with defect : 1 % Vehicle Information : Vehicle 1 : 2022-2023 Toyota Tundra Vehicle Type : Body Style : Power Train : NR Descriptive Information : Although the involved vehicles are within the above production period range, not all vehicles in this range were sold in the U.S. This issue only affects certain Tundra and Tundra Hybrid vehicles equipped with a fuel tube assembly and surrounding components of a specific design prior to production changes to protect and secure the fuel tube. Other Toyota or Lexus vehicles sold in the U.S. are not equipped with a fuel tube and surrounding components of this design and are not affected by the condition described in Section 5 below. 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”. Production Dates : NOV 02, 2021 – JUL 24, 2023 VIN Range 1 : Begin : NR End : NR Not sequential Part 573 Safety Recall Report 23V-566 Page 2 The information contained in this report was submitted pursuant to 49 CFR §573 Vehicle 2 : 2022-2023 Toyota Tundra Hybrid Vehicle Type : Body Style : Power Train : NR Descriptive Information : Although the involved vehicles are within the above production period range, not all vehicles in this range were sold in the U.S. This issue only affects certain Tundra and Tundra Hybrid vehicles equipped with a fuel tube assembly and surrounding components of a specific design prior to production changes to protect and secure the fuel tube. Other Toyota or Lexus vehicles sold in the U.S. are not equipped with a fuel tube and surrounding components of this design and are not affected by the condition described in Section 5 below. 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”. Production Dates : MAR 15, 2022 – JUN 07, 2023 VIN Range 1 : Begin : NR End : NR Not sequential Description of Defect : Description of the Defect : 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. FMVSS 1 : NR FMVSS 2 : NR Description of the Safety Risk : 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. Description of the Cause : NR Identification of Any Warning that can Occur : NR Involved Components : Part 573 Safety Recall Report 23V-566 Page 3 The information contained in this report was submitted pursuant to 49 CFR §573 Component Name 1 : Tube Sub-Assy. Fuel Tank Main Component Description : Fuel Tube Assembly Component Part Number : 77209-0C180 Supplier Identification : Component Manufacturer Name : Textron Inc. (Corporate) Address : 40 Westminster Street Providence Rhode Island 02903 Country : United States Chronology : Please see 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 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. 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 October 9, 2023. A copy of the draft owner notification will be submitted as soon as it is available. Notifications to distributors/dealers will be sent on August Part 573 Safety Recall Report 23V-566 Page 4 The information contained in this report was submitted pursuant to 49 CFR §573 10, 2023. Copies of dealer communications will be submitted as they are issued. Planned Dealer Notification Date : AUG 10, 2023 – AUG 10, 2023 Planned Owner Notification Date : SEP 25, 2023 – OCT 09, 2023 * NR – Not Reported
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