23TA16 – Passenger Airbag May Not Deploy as Designed – 2022-2023 Toyota Corolla Cross

SEOCONTENT-START

TOYOTA
Toyota Motor North America, Inc.
Vehicle Safety & Compliance Liaison Office
Mail Stop: W4-2D
6565 Headquarters Drive
Plano, TX 75024
December 20, 2023
NONCOMPLIANCE INFORMATION REPORT
1. Vehicle Manufacturer Name:
Mazda Toyota Manufacturing U.S.A., Inc [“MTMUS”] 9000 Greenbriar Parkway, NW, Madison, AL 35756
Affiliated U.S. Sales Company
Toyota Motor North America, [“TMNA”] 6565 Headquarters Drive, Plano, TX 75024
Manufacturer of the Instrument Panel Safety Pad Assembly
Vuteq -Alabama
7036 Greenbrier Parkway, NW, Madison, AL 35756
Phone: +1(256) 274-3308
Country of Origin: United States
2. Identification of Involved Vehicles:
Based on production records, we have determined the involved vehicle population to be the vehicles listed in the table below.
Make/Car Line
Model Year
Manufacturer
Production Period
Toyota/Corolla Cross
2022 – 2023
MTMUS
September 7, 2021
through
May 4, 2023
Applicability
Part Number
Part Name
Component Description
MY2022-2023 Toyota/Corolla Cross
55400-0A050
Pad Assy, Instrument Panel Safety
Instrument Panel 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 involves the subject vehicles which were assembled with instrument panel assemblies produced by a specific supplier during a specific production period, and which now require reinspection after having been inspected in connection with recall 23V-384.
3. Total Number of Vehicles Involved:
12,575
4. Percentage of Vehicles Estimated to Actually Contain the Noncompliance:
As stated in the Noncompliance Information Report (23V-384), “1.77%. This estimate is based on production records of 2,029 suspect parts out of the total vehicles produced for the U.S. and other countries that could contain the part affected by the condition described below in Section 5.”
5. Description of Noncompliance:
This supplements the Noncompliance Information Report (23V-384) filed on May 30, 2023, which described the noncompliance as follows: “The subject vehicles are equipped with an instrument panel that contains an airbag at the right front passenger’s seating position. The instrument panel is designed to contain a perforation that will open during front passenger airbag deployment. Due to incorrectly followed production work instructions in the instrument panel milling process at a certain supplier, there is a possibility that the instrument panel was produced without the perforation. This could result in an airbag deployment in a manner other than as designed in the event of a crash of the type that would cause deployment. As a result, the vehicles may not comply with certain requirements of FMVSS No. 208 S14.4. This could result in an increased risk of injury during a crash.”
6. Test Results and Other Information:
After launching the remedy for Recall 23V-384, Toyota began to receive reports from dealers of serial numbers which had already been reported by a different dealer. Toyota began an investigation. It subsequently determined that the vehicles identified in Section 3 above required reinspection.
Toyota met with the agency’s Recall Management Division on December 12, 2023, to further explain the need for the reinspection. The agency requested that this should be done under a separate recall identification for accounting purposes.
7. Description of Corrective Repair Action:
All known owners of the involved vehicles will be notified via first class mail to return their vehicles to a Toyota dealer. For all involved vehicles, Toyota dealers will re-inspect, and, if necessary, replace the instrument panel at no cost to owners.
Reimbursement Plan for pre-notification remedies
As the owner notification letters will be mailed out well within the active period of the Toyota New Vehicle Limited Warranty (“Warranty”), all involved vehicle owners for this recall would have been provided a repair at no cost under Toyota’s Warranty.
8. Recall Schedule:
Notifications to owners of the affected vehicles will occur by February 18, 2024. A copy of the draft owner notification letter(s) will be submitted as soon as available.
9. Distributor/Dealer Notification Schedule:
Notifications to distributors/dealers will be sent by December 20, 2023. Copies of dealer communications will be submitted as they are issued.
10. Manufacturer’s Campaign Number:
23TA16

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© 2023 Toyota Motor Sales, USA
INTEROFFICE MEMORANDUM
Original Publication Date: December 20, 2023
To: All Toyota Region and Private Distributor General Managers / Vice Presidents From: Gary Ross
Vice-President, Product Quality and Service Support SAFETY (NONCOMPLIANCE) RECALL 23TA16 (Remedy Notice) Certain 2022-2023 Model Year Corolla Cross Passenger Airbag May Not Deploy as Designed
Condition The subject vehicles were previously inspected under a prior recall. Due to a problem with the inspection process specified by Toyota, the inspection may not have identified certain vehicles requiring the remedy. Without the remedy, the front passenger airbag may not deploy as designed due to a manufacturing error in the instrument panel where the airbag is located. As a result, the vehicles may not meet certain federal requirements, and there could be an increased risk of injury in a crash.
Dealer Notification
The attached dealer letter will be sent to all Toyota dealers on December 20, 2023. Please reference the attached Dealer Letter for additional details. Please review this notification with your staff to assure that all relevant personnel have been briefed regarding this subject.
Thank you for your cooperation.

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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: December 20, 2023 To: All Toyota Dealer Principals, General Managers, Service Managers, and Parts Managers SAFETY (NONCOMPLIANCE) RECALL 23TA16 (Remedy Notice) Certain 2022-2023 Model Year Corolla Cross Passenger Airbag May Not Deploy as Designed
Model / Years Production Period Approximate Total
Approximate Stop Sale Dealer Inventory 2022-2023 Corolla Cross Early September 2021 – Early May 2023 12,600 8
STOP! DO NOT SELL NEW VEHICLES IN DEALER INVENTORY.
Refer to Dealer Inventory Procedures section for more details.
On December 20, 2023, Toyota filed a Noncompliance Information Report (NCIR) with the National Highway Traffic Safety Administration (NHTSA) informing the agency of our intent to conduct a voluntary Safety (Noncompliance) Recall on certain 2022-2023 model year Corolla Cross vehicles. Condition
The subject vehicles were previously inspected under a prior recall. Due to a problem with the inspection process specified by Toyota, the inspection may not have identified certain vehicles requiring the remedy. Without the remedy, the front passenger airbag may not deploy as designed due to a manufacturing error in the instrument panel where the airbag is located. As a result, the vehicles may not meet certain federal requirements, and there could be an increased risk of injury in a crash. Remedy
For all involved vehicles, Toyota dealers will re-inspect with an improved process, and, if necessary, replace the instrument panel FREE OF CHARGE. Until the vehicle is inspected and the remedy is performed, if necessary, Toyota recommends that no one sit in the front passenger seat of an involved vehicle. Covered Vehicles
There are approximately 12,600 vehicles covered by this Safety (Noncompliance) Recall. Approximately 900 vehicles involved in this Safety Recall were distributed to Puerto Rico. Owner Letter Mailing Date
Toyota will notify owners by early February 2024. S a f e t y ( N o n c o m p l i a n c e ) R e c a l l 2 3 T A 1 6 – P a g e | 2 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 (Noncompliance) 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. © 2023 Toyota Motor Sales, USA S a f e t y ( N o n c o m p l i a n c e ) R e c a l l 2 3 T A 1 6 – P a g e | 3
Dealer Inventory Procedures New Vehicles in Dealership Inventory
There are approximately 8 vehicles in new dealer inventory as of December 14, 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. © 2023 Toyota Motor Sales, USA S a f e t y ( N o n c o m p l i a n c e ) R e c a l l 2 3 T A 1 6 – P a g e | 4 Inspection Reminder Mirror Hang Tags for Covered Vehicles in New Dealer Stock
To easily recognize vehicles involved in this Safety (Noncompliance) 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. NOTE: Dealerships can order hang tags from the Material Distribution Center (MDC). Part Number 00411-140003 Description Inspection Mirror Hang Tag Quantity 25 Per Pack Pre-Owned Vehicles in Dealer Inventory
To ensure customer satisfaction, Toyota requests that dealers complete this Safety Recall on any used vehicles currently in dealer inventory that are covered by this Safety Recall prior to customer delivery. However, if the campaign cannot be completed (for example, due to remedy parts availability), delivery of a covered vehicle is acceptable if disclosed to the customer that the vehicle is involved in a Safety Recall. 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 23TA16/23TB16” 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. © 2023 Toyota Motor Sales, USA S a f e t y ( N o n c o m p l i a n c e ) R e c a l l 2 3 T A 1 6 – P a g e | 5
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 (Noncompliance) 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 (Noncompliance) 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 (Noncompliance) 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 (Noncompliance) 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. Parts Ordering Process – Non SET and GST Parts Ordering Process
It is possible that parts for this campaign are either required to be ordered in Campaign Part Order Request (CPOR) on Service Lane, or have been placed on Manual Allocation Control (MAC) due to potential limited part availability. Please check the CPOR/MAC report on Dealer Daily for the most up-to-date parts ordering information. Dealers can identify which parts ordering method to use by reviewing the parts information section of Dealer Daily and checking for a MAC code on the part numbers below. For MAC code C, order through CPOR. For MAC code D, refer to the MAC report for further instructions. © 2023 Toyota Motor Sales, USA S a f e t y ( N o n c o m p l i a n c e ) R e c a l l 2 3 T A 1 6 – P a g e | 6 All Safety Recall, Service Campaign (SSC/LSC) parts are eligible for the Monthly Parts Return Program. Please refer to PANT Bulletin 2011-087 for campaign parts that are currently returnable under the Monthly Parts Return Program and for additional details. No parts are needed for the QR code inspection. In the rare case that the vehicle fails the initial QR code inspection, reference the parts table below for parts required. Milling Inspection Parts (Clips are required for this inspection)
Part Number Part Description Quantity
62217-42050 CLIP, FR PILLAR GARNISH 4 If Replacement is Required
Part Number Part Description Quantity
55400-0A050-C0 Pad Assy, Instrument Panel 1
62217-42050 CLIP, FR PILLAR GARNISH 4 Technician Training Requirements
The repair quality of covered vehicles is extremely important to Toyota. All dealership technicians performing this repair are required to successfully complete the most current version of the E-Learning course “Safety Recall and Service Campaign Essentials”. To ensure that all vehicles have the repair performed correctly; technicians performing this repair are required to have currently completed the following courses: • TIC206A – Electrical Repair 1 Always check which technicians can perform the repair by logging on to https://www.uotdealerreports.com. It is the dealership’s responsibility to select technicians with the above certification level or greater to perform this repair. Carefully review your resources, the technician skill level, and ability before assigning technicians to this repair. It is important to consider technician days off and vacation schedules to ensure there are properly trained technicians available to perform this repair at all times. Remedy Procedures
Refer to TIS for Technical Instructions on repair. Conduct all non-completed Safety Recalls and Service Campaigns on the vehicle during the time of appointment. Repair Quality Confirmation
The repair quality of covered vehicles is extremely important to Toyota. To help ensure that all vehicles have the repair performed correctly, please designate at least one associate (someone other than the individual who performed the repair) to verify the repair quality of every vehicle prior to customer delivery. Parts Recovery Procedures
All parts replaced as part of this Safety Recall must be turned over to the parts department until appropriate disposition is determined. The parts department must retain these parts until notification via the Parts Recovery System (PRS) is received indicating whether to ship or scrap the parts. These parts are utilized by © 2023 Toyota Motor Sales, USA S a f e t y ( N o n c o m p l i a n c e ) R e c a l l 2 3 T A 1 6 – P a g e | 7 various departments for defect analysis, quality control analysis, product evaluation, as well as other purposes. To help minimize dealer storage challenges, Toyota recommends that dealers:
• File the campaign claim accurately and promptly. The time a dealer is required to hold parts is based on when the campaign claim is paid by Toyota.
• Monitor the Warranty Parts Recovery Notifications and Part Scrap Report regularly. Refer to Warranty Policies 9.3 and 9.6 for additional details. © 2023 Toyota Motor Sales, USA S a f e t y ( N o n c o m p l i a n c e ) R e c a l l 2 3 T A 1 6 – P a g e | 8 Warranty Reimbursement Procedures Warranty Reimbursement Procedure Verify Vehicle Eligibility
• Confirm vehicle VIN matches the RO
• Check for Campaign eligibility using TIS Not Covered No Further Action Required Covered Inspect Instrument Panel Serial Number Not Affected Affected Refer to TI for secondary inspection.
Are the Milling marks Missing? No Yes Replace Instrument Panel Follow TI for repair instructions Campaign completed, return the vehicle to the customer. Op Code 23TA16R1
23TA16R2
23TA16R3 Description
Inspect Instrument Panel Serial Number Inspect + Secondary Inspection for Milling Marks
Inspect + Replace the Instrument Panel Flat Rate Hours 0.3
4.3
4.3 • The flat rate times include 0.1 hours for administrative cost per unit for the dealership.
• A loaner vehicle or alternative transportation through the Toyota Rent-A-Car (TRAC) program can be claimed up to a maximum of 2 days as a sublet type “RT” under Op Code 23TA16R3.
o For rentals that exceed the maximum number of allowable days and/or dollars per day, refer to the Toyota Transportation Assistance Policy (TTAP) for DSPM authorization requirements.
o Rental invoice MUST be attached to all rental claims. These claims may be subject to debit if rental invoice is not attached. Claim Filing Accuracy and Correction Requests
It is the dealer’s responsibility to file claims correctly for this Safety (Noncompliance) Recall. This claim filing information is used by Toyota for various government reporting activities; therefore, claim filing accuracy is crucial. If it has been identified that a claim has been filed using an incorrect Op Code or a claim has been filed for an incorrect VIN, refer to Warranty Procedure Bulletin PRO17-03 to correct the claim. © 2023 Toyota Motor Sales, USA S a f e t y ( N o n c o m p l i a n c e ) R e c a l l 2 3 T A 1 6 – P a g e | 9 Campaign Designation / Phase Decoder 23TA16 23 T A 16 Year Campaign is Launched Vehicle Make Field Action Category and Phase Field Action Sequence 19 = 2019
20 = 2020
21 = 2021
22 = 2022
23 = 2023
Etc… Examples: T = Toyota L = Lexus 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) 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) 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 (Noncompliance) Recall. Thank you for your cooperation. TOYOTA MOTOR SALES, U.S.A., INC. © 2023 Toyota Motor Sales, USA SAFETY (NONCOMPLIANCE) RECALL 23TA16 (Remedy Notice) Certain 2022-2023 Model Year Corolla Cross Passenger Airbag May Not Deploy as Designed Frequently Asked Questions
Original Publication Date: December 20, 2023 Q1: What is the condition?
A1: The subject vehicles were previously inspected under a prior recall. Due to a problem with the inspection process specified by Toyota, the inspection may not have identified certain vehicles requiring the remedy. Without the remedy, the front passenger airbag may not deploy as designed due to a manufacturing error in the instrument panel where the airbag is located. As a result, the vehicles may not meet certain federal requirements, and there could be an increased risk of injury in a crash. Q2: What is Toyota going to do?
A2: Any authorized Toyota dealer will re-inspect with an improved process, and if necessary, replace the instrument panel FREE OF CHARGE. Until the vehicle is re-inspected and the remedy is performed, if necessary, Toyota recommends that no one sit in the front passenger seat of an involved vehicle. Q3: Why is my vehicle being re-inspected after I had 23TA04 completed?
A3: After launching the prior recall remedy, Toyota learned that certain vehicles inspected under the recall may not have identified those requiring the remedy due to a problem with the inspection process specified by Toyota. As such, Toyota has adjusted its inspection method and will re-inspect the vehicles. Q3a: My vehicle is already completed for Safety Recall 23TA04; am I involved in Safety Recall 23TA16?
A3a: Only certain vehicles under Safety Recall 23TA04 are included in Safety Recall 23TA16. Please contact any authorized Toyota dealer to confirm whether your vehicles is involved in 23TA16 or visit www.toyota.com/recall and enter your VIN or license plate to see if you are affected. Q4: Which and how many vehicles are covered by this Safety (Noncompliance) Recall?
A4: There are approximately 12,600 vehicles covered by this Safety (Noncompliance) Recall. Model Name Corolla Cross Model Year 2022-2023 Production Period
Early September 2021- Early May 2023
FAQ Page 1 of 2 © 2023 Toyota Motor Sales, USA FAQ Page 2 of 2
© 2023 Toyota Motor Sales, USA
Q5: How long will the repair take?
A5: For most vehicles, an initial inspection will only take a few minutes. If the instrument panel does not pass initial inspection, a small percentage of vehicles will require a more detailed inspection and replacement of the instrument panel, if necessary, which could take approximately 4 hours. 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.

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OMB Control No.: 2127-0004
Part 573 Safety Recall Report 23V-864
The information contained in this report was submitted pursuant to 49 CFR §573
Manufacturer Name : Submission Date :
Toyota Motor Engineering & Manufacturing DEC 20, 2023 NHTSA Recall No. : 23V-864 Manufacturer Recall No. : 23TA16
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 : 12,575 Estimated percentage with defect : 2 %
Vehicle Information :
Vehicle 1 : 2022-2023 Toyota Corolla Cross 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 involves the subject vehicles which were assembled with instrument panel assemblies produced by a specific supplier during a specific production period, and which now require reinspection after having been inspected in connection with recall 23V-384.As stated in the Noncompliance Information Report (23V-384), “1.77%. This estimate is based on production records of 2,029 suspect parts out of the total vehicles produced for the U.S. and other countries that could contain the part affected by the condition described below in Section 5.” Production Dates : SEP 07, 2021 – MAY 04, 2023
VIN Range 1 : Begin : NR End : NR Not sequential Part 573 Safety Recall Report 23V-864 Page 2 Description of Noncompliance : Description of the Noncompliance : This supplements the Noncompliance Information Report (23V-384) filed on May 30, 2023, which described the noncompliance as follows: “The subject vehicles are equipped with an instrument panel that contains an airbag at the right front passenger’s seating position. The instrument panel is designed to contain a perforation that will open during front passenger airbag deployment. Due to incorrectly followed production work instructions in the instrument panel milling process at a certain supplier, there is a possibility that the instrument panel was produced without the perforation. This could result in an airbag deployment in a manner other than as designed in the event of a crash of the type that would cause deployment. As a result, the vehicles may not comply with certain requirements of FMVSS No. 208 S14.4. This could result in an increased risk of injury during a crash.” FMVSS 1 : 208 – Occupant crash protection FMVSS 2 : NR
Description of the Safety Risk : This could result in an airbag deployment in a manner other than as designed in the event of a crash of the type that would cause deployment. As a result, the vehicles may not comply with certain requirements of FMVSS No. 208 S14.4. This could result in an increased risk of injury during a crash.
Description of the Cause : NR Identification of Any Warning NR
that can Occur : Involved Components : Component Name 1 : Pad Assy, Instrument Panel Safety Component Description : Instrument Panel Assembly Component Part Number : 55400-0A050 Supplier Identification : Component Manufacturer
Name : Vuteq – Alabama
Address : 7036 Greenbrier Parkway, NW Madison Alabama 35756
Country : United States The information contained in this report was submitted pursuant to 49 CFR §573 Part 573 Safety Recall Report 23V-864
Page 3
The information contained in this report was submitted pursuant to 49 CFR §573
Chronology :
After launching the remedy for Recall 23V-384, Toyota began to receive reports from dealers of serial numbers which had already been reported by a different dealer. Toyota began an investigation. It subsequently determined that the vehicles identified in Section 3 above required reinspection. Toyota met with the agency’s Recall Management Division on December 12, 2023, to further explain the need for the reinspection. The agency requested that this should be done under a separate recall identification for accounting purposes.
Description of Remedy :
Description of Remedy Program : All known owners of the involved vehicles will be notified via first class
mail to return their vehicles to a Toyota dealer. For all involved vehicles, Toyota dealers will re-inspect, and, if necessary, replace the instrument panel at no cost to owners. As the owner notification letters will be mailed out well within the active period of the Toyota New Vehicle Limited Warranty (“Warranty”), all involved vehicle owners for this recall would have been provided a repair at no cost under Toyota’s Warranty.
How Remedy Component Differs NR from Recalled Component :
Identify How/When Recall Condition NR was Corrected in Production :
Recall Schedule :
Description of Recall Schedule : Notifications to owners of the affected vehicles will occur by February 18,
2024. A copy of the draft owner notification letter(s) will be submitted as soon as available. Notifications to distributors/dealers will be sent by December 20, 2023. Copies of dealer communications will be submitted as they are issued.
Planned Dealer Notification Date : DEC 20, 2023 – DEC 20, 2023
Planned Owner Notification Date : FEB 04, 2024 – FEB 18, 2024
* NR – Not Reported

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