24TA06 – Rear Door May Open While Driving – 2023-2024 Toyota Prius & Prius Prime

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April 17, 2024 NHTSA CAMPAIGN NUMBER: 24V274000

Unlocked Rear Door May Open Unexpectedly

A door that unexpectedly opens while the vehicle is moving or during a crash increases the risk of injury.

 

NHTSA Campaign Number: 24V274

Manufacturer Toyota Motor Engineering & Manufacturing

Components ELECTRICAL SYSTEM, LATCHES/LOCKS/LINKAGES

Potential Number of Units Affected 55,690

 

Summary

Toyota Motor Engineering & Manufacturing (Toyota) is recalling certain 2023-2024 Prius and Prius Prime vehicles. Water may enter the rear door switch and cause a short circuit, allowing an unlocked rear door to open unexpectedly.

 

Remedy

Dealers will replace both right and left rear door opener switches, free of charge. Owner notification letters are expected to be mailed June 2, 2024. Owners may contact Toyota customer service at 1-800-331-4331. Toyota’s numbers for this recall are 24TB06 and 24TA06.

 

Notes

Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.nhtsa.gov.

 

Check if your Vehicle has a Recall

 


SAFETY RECALL 24TA06 (Interim Notice 24TB06)

Certain 2023 – 2024 Model Year Prius and Prius Prime
Rear Door May Open While Driving

On April 17, 2024, 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 2023 – 2024 model year Prius and Prius Prime vehicles.

 

Condition

Water can enter and short circuit the electronic rear door latches in the involved vehicles.  If the doors are not locked, they could open while the vehicle is moving or in a crash, increasing the risk of injury to occupants.

 

Remedy

Toyota is currently preparing the remedy for this issue. When the remedy is available, Toyota dealers will replace both right and left rear door opener switches with improved ones FREE OF CHARGE. At this time, Toyota estimates the remedy can be available in the third quarter of 2024.

 

Covered Vehicles

There are approximately 55,700 vehicles covered by this Safety Recall. Approximately 260 vehicles involved in this Safety Recall were distributed to Puerto Rico.

 

Owner Letter Mailing Date

Toyota will notify owners by early June 2024.

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.

 


Frequently Asked Questions
Original Publication Date: April 17, 2024

Q1: What is the condition?

A1: Water can enter and short circuit the electronic rear door latches in the involved vehicles. If the doors are not locked, they could open while the vehicle is moving or in a crash, increasing the risk of injury to occupants.

 

Q2: What is Toyota going to do?

A2: Toyota is currently preparing the remedy for this issue. When the remedy is available, Toyota dealers will replace both right and left rear door opener switches with improved ones FREE OF CHARGE. At this time, Toyota estimates the remedy can be available in the third quarter of 2024.

 

Q3: When will the remedy become available?

A3: Toyota is currently preparing the parts and repair instructions for the remedy. At this time, Toyota estimates that the remedy can be available in the third quarter of 2024.

 

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

A4: There are approximately 55,700 vehicles covered by this Safety Recall.

Model / Years Production Period Approximate Total Vehicles
2023 – 2024 Prius Early October 2022 – Early April 2024 42,600
2023 – 2024 Prius Prime Early October 2022 – Early April 2024 13,100

 

Q4a: Are there any other Lexus/Toyota/Scion vehicles covered by this Safety Recall in the U.S.?

A4a: No, there are no other Lexus/Scion vehicles covered by this Safety Recall.

Q5: Are there any warnings that this condition exists?

A5: Yes, if a short-circuit occurs that causes a door to open, there will be a notification on the combination meter, and a buzzer will sound if the vehicle is in motion.

 

Q6: Are there any preventative measures I can take to reduce the possibility of the door opening unexpectedly?

A6: Yes. You can avoid large water splashes in the rear door(s) area such as pressure washing or automatic car washes.
Also, ensure that the doors on your vehicle automatically lock when you shift from “Park”. If they don’t, you can enable this automatic door locking function through your vehicle’s head unit following the steps shown below. This procedure can only be completed while vehicle is in Park. Please contact your local Toyota dealer for additional assistance free of charge if necessary.

 

Q7: How does Toyota obtain my mailing information?

A7: 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.

 

Q8: What if I have additional questions or concerns?

A8: If you have additional questions or concerns, please contact the Toyota Brand Engagement Center at 1-800-331-4331 Monday through Friday, 8:00 am to 8:00 pm, Saturday 9:00 am to 7:00 pm Eastern Time.

 


Description of Problem:

The subject vehicles are equipped with an electric rear door lock system which includes a door opener switch and a rear door lock release actuator to release the latch from outside of the vehicle. Due to insufficient waterproofing of the door opener switch, if a large amount of water splashes on the switch (for example, at a car wash), there is a possibility that the water could enter the switch and cause a short circuit. If the door is not locked, the short circuit could cause the door to open unexpectedly. If this occurs, there will be a notification on the combination meter, and a buzzer will sound if the vehicle is in motion. A door opening while the vehicle is moving or during a crash could increase the risk of injury to occupants.

 

Chronology of Principal Events:

Early March 2024 – Mid April 2024
In early March 2024, Toyota received a field report about a vehicle in the Japan market indicating that a left rear door suddenly opened while driving. During the dealer inspection, an abnormality was found in the voltage value between certain connector terminals of the door opener switch mounted on the left rear door outside handle. The left rear door outside handle was recovered and sent to the supplier for the further investigation.

During the investigation of the recovered part, the supplier found signs of water intrusion on the circuit board inside the door opener switch. Toyota began investigating how water can bypass the rear door outside handle and contact the sealed portion of the switch by conducting water splash testing. It was found that water from the outside can reach and contact the sealed portion of the switch by passing through gaps between components of the door outside handle if water is sprayed (via handheld pressure washer) directly on the door opener switch.

From the above results, in order to understand how water can enter through the switch body and sealant, the supplier performed water immersion testing using new door opener switches, but was unable to reproduce water intrusion on these switches. Toyota and the supplier hypothesized that the sealant could partially separate from the switch body in normal usage of the vehicle and in temperature variations.

The supplier then compared material characteristics of both the switch body and sealant. Toyota found that there was a difference in the thermal expansion coefficient between the switch body and sealant. Toyota and the supplier presumed that the partial separations of sealant were caused by repeated thermal expansion and contraction during vehicle use.
The supplier then performed water immersion testing using switches that had experienced thermal cycle testing. As a result, Toyota confirmed that water entered from the interface between the switch body and sealant in one of the switches.

Based on the above investigations, Toyota determined that the sealant used on the switch body may partially separate due to thermal expansion and contraction in normal vehicle use, leading to insufficient waterproof performance. In this condition, if a large amount of water splashes on the switch (for example, at a car wash), the water could enter the switch and cause a short circuit. If the door is not locked (for example, in case an automatic door lock feature is set to deactivate), the short circuit could cause the door to open unexpectedly.

April 11, 2024
Based on the results of the above investigation, Toyota decided to conduct a voluntary safety recall campaign.

As of April 10, 2024, based on a diligent review of records, Toyota’s best engineering judgment is that there are no Toyota Field Technical Reports and no warranty claim 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 dealer will replace both right and left rear door opener switches with improved ones, free of charge.
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.

 

Recall Schedule:

Notifications to owners of the affected vehicles will occur by June 16, 2024. A copy of the draft owner notification will be submitted as soon as it is available.

 


4 Affected Products

Vehicles

MAKE MODEL YEAR
TOYOTA PRIUS 2023-2024
TOYOTA PRIUS PRIME 2023-2024

 


4 Associated Documents

Manufacturer Notices(to Dealers,etc)

RCMN-24V274-2871.pdf 344.405KB

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Defect Notice 573 Report

RCLRPT-24V274-3413.PDF 215.881KB

 


Recall Acknowledgement

RCAK-24V274-1822.pdf 731.703KB

 


Miscellaneous Document

RMISC-24V274-0258.pdf 129.283KB

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Latest Recalls Documents

For the Latest and Most recent Recall Information Visit the link below…

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=24V274&docType=RCL

 


 

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Last update on 2024-04-20 / Affiliate links / Images from Amazon Product Advertising API

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