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

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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
April 17, 2024
DEFECT INFORMATION REPORT
1. Vehicle Manufacturer Name:
Toyota Motor Corporation [“TMC”]
1, Toyota-cho, Toyota-city, Aichi-pref., 471-8571, Japan
Affiliated U.S. Sales Company:
Toyota Motor North America, Inc. [“TMNA”]
6565 Headquarters Drive, Plano, TX 75024
Manufacturer of Rear door outside handle:
TOKAI RIKA CO., LTD.
3-260 Toyota, Oguchi-cho, Niwa-gun, Aichi-pref. 480-0195, Japan
Telephone: +81-587-95-5211
Country of Origin: Japan
2. Identification of Involved Vehicles and Affected Components:
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 / Prius
2023-2024 TMC
October 11, 2022
through
April 3, 2024
Toyota / Prius
Prime
October 13, 2022
through
April 3, 2024
Applicability
Part Number
Part Name
Component Description
MY2023-2024 Toyota Prius,
Prius Prime
69230-47060
Switch Assy,
RR Door Handle Opener RH
Right rear door outside handle
69240-47040
Switch Assy,
RR Door Handle Opener LH
Left rear door outside handle
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 MY 2023-2024 Prius/Prius Prime vehicles equipped with rear door outside handles with a door opener switch manufactured by a specific supplier and during a specific production period. Other Toyota or Lexus vehicles sold in the U.S. are not equipped with a door opener switch or are equipped with a different door opener switch and do not have the condition described in this report.
3. Total Number of Vehicles Potentially Involved:
Prius : 42,561
Prius Prime : 13,129
Total : 55,690
4. Percentage of Vehicles Estimated to Actually Contain the Defect:
Unknown. Toyota is unable to provide an estimate of the percentage of vehicles to actually contain the defect. Whether a sufficient amount of water enters the door opener switch and causes a short circuit that could lead to a door opening depends on various conditions, as described further below. 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 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.
6. 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.
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 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.
8. 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.
9. Distributor/Dealer Notification Schedule:
Notifications to distributors/dealers will be sent on April 17, 2024. Copies of dealer communications will be submitted as they are issued.
10. Manufacturer’s Campaign Number:
Interim / Remedy: 24TB06 / 24TA06

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© 2024 Toyota Motor Sales, USA
Toyota Motor Sales, USA, Inc.
6565 Headquarters Drive
Plano, TX 75024
(469) 292-4000
Original Publication Date: April 17, 2024
To:
All Toyota Dealer Principals, General Managers, Service Managers, and Parts Managers
SAFETY RECALL 24TA06 (Interim Notice 24TB06)
Certain 2023 – 2024 Model Year Prius and Prius Prime
Rear Door May Open While Driving
Model / Years
Production Period
Approximate Total Vehicles
Approximate Stop Sale Dealer Inventory
2023 – 2024 Prius
Early October 2022 – Early April 2024
42,600
1,000
2023 – 2024 Prius Prime
Early October 2022 – Early April 2024
13,100
800
STOP! DO NOT SELL NEW VEHICLES IN DEALER INVENTORY. Refer to Dealer Inventory Procedures section for more details.
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.
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© 2024 Toyota Motor Sales, USA
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.
Dealer Inventory Procedures
New Vehicles in Dealership Inventory
There are approximately 1,800 vehicles in new dealer inventory as of April 15, 2024.
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 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.
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© 2024 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.
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 visit https://toyota-recall-disclosure.imagespm.info/ and complete a Customer Contact and Vehicle Disclosure Form. 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.
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
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© 2024 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 (1-800-331-4331) – 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 the Toyota Newsroom https://pressroom.toyota.com/
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© 2024 Toyota Motor Sales, USA
Campaign Designation / Phase Decoder
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 5
© 2024 Toyota Motor Sales, USA
SAFETY RECALL 24TA06 (Interim Notice 24TB06)
Certain 2023 – 2024 Model Year Prius and Prius Prime
Rear Door May Open While Driving
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.
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© 2024 Toyota Motor Sales, USA
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.
FAQ Page 3 of 5
© 2024 Toyota Motor Sales, USA
Enable Automatic Door Locking Function Steps
Step 1: Ensure vehicle is in Park.
Step 2: Access the Settings menu by pressing the gear on the bottom left as shown below.
Step 3: Select Vehicle customize menu as shown below.
FAQ Page 4 of 5
© 2024 Toyota Motor Sales, USA
Step 4: Select Door control as shown below.
Step 5: Ensure “Shift from park” from Auto lock menu is selected as shown below.
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© 2024 Toyota Motor Sales, USA
Example of correct menu selection is shown below.
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.

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OMB Control No.: 2127-0004
Part 573 Safety Recall Report 24V-274
The information contained in this report was submitted pursuant to 49 CFR §573
Manufacturer Name : Submission Date :
Toyota Motor Engineering & Manufacturing APR 17, 2024 NHTSA Recall No. : 24V-274 Manufacturer Recall No. : 24TB06 / 24TA06
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 : 55,690 Estimated percentage with defect : 1 %
Vehicle Information :
Vehicle 1 : 2023-2024 Toyota Prius 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 MY 2023-2024 Prius/Prius Prime vehicles equipped with rear door outside handles with a door opener switch manufactured by a specific supplier and during a specific production period. Other Toyota or Lexus vehicles sold in the U.
S. are not equipped with a door opener switch or are equipped with a different door opener switch and do not have the condition described in this report. Unknown. Toyota is unable to provide an estimate of the percentage of vehicles to actually contain the defect. Whether a sufficient amount of water enters the door opener switch and causes a short circuit that could lead to a door opening depends on various conditions, as described further below. 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 : OCT 11, 2022 – APR 03, 2024
VIN Range 1 : Begin : NR End : NR Not sequential Part 573 Safety Recall Report 24V-274 Page 2 Vehicle 2 : 2023-2024 Toyota Prius Prime 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 MY 2023-2024 Prius/Prius Prime vehicles equipped with rear door outside handles with a door opener switch manufactured by a specific supplier and during a specific production period. Other Toyota or Lexus vehicles sold in the U.
S. are not equipped with a door opener switch or are equipped with a different door opener switch and do not have the condition described in this report. Unknown. Toyota is unable to provide an estimate of the percentage of vehicles to actually contain the defect. Whether a sufficient amount of water enters the door opener switch and causes a short circuit that could lead to a door opening depends on various conditions, as described further below. 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 : OCT 13, 2022 – APR 03, 2024
VIN Range 1 : Begin : NR End : NR Not sequential Description of Defect :
Description of the Defect : 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.
FMVSS 1 : NR FMVSS 2 : NR
Description of the Safety Risk : 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.
Description of the Cause : NR Identification of Any Warning NR
that can Occur : The information contained in this report was submitted pursuant to 49 CFR §573 Part 573 Safety Recall Report 24V-274 Page 3 Involved Components : Component Name 1 : Switch Assy, RR Door Handle Opener RH Component Description : Right rear door outside handle Component Part Number : 69230-47060 Component Name 2 : Switch Assy, RR Door Handle Opener LH Component Description : Left rear door outside handle
Component Part Number : 69240-47040 Supplier Identification : Component Manufacturer
Name : TOKAI RIKA CO., LTD.
Address : 3-260 Toyota, Oguchi-cho, Niwa-gun Aichi-pref. Foreign States 480-0195
Country : Japan Chronology :
Please see attached Part 573 Defect Information Report for 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 dealer will replace both right and left rear door opener switches with improved ones, free of charge. 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 : The information contained in this report was submitted pursuant to 49 CFR §573 Part 573 Safety Recall Report 24V-274
Page 4
The information contained in this report was submitted pursuant to 49 CFR §573
Recall Schedule :
Description of 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. Notifications to distributors/dealers will be sent on April 17, 2024. Copies of dealer communications will be submitted as they are issued.
Planned Dealer Notification Date : APR 17, 2024 – APR 17, 2024
Planned Owner Notification Date : JUN 02, 2024 – JUN 16, 2024
* NR – Not Reported

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