SAFETY RECALL KLC – Possible Partial Tread Separation of Run-Flat Tires – 2018 Lexus LS 500 & LS 500h

SEOCONTENT-STARTTOYOTA
Toyota Motor North America, Inc.
Vehicle Safety & Compliance
Liaison Office
Mail Stop: W4-2D
6565 Headquarters Drive
Plano, TX 75024
February 27, 2019
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
Assembler of run-flat tire to wheel:
Topy Industries, Ltd.
1-2-2 Osaki, Shinagawa-ku, Tokyo, 141-8634, Japan
Telephone: +81-3-3493-0777
Country of Origin: Japan
2. Identification of Involved Vehicles:
Make/Car Line
Model Year
Manufacturer
Production Period
Lexus / LS
2018
TMC
February 21, 2017
through
July 20, 2018
Applicability
Part Number
Part Name
Component Description
MY2018 Lexus LS
42600-5AG80
Wheel Assy
Wheel with run-flat tire
42600-5AM80
42600-5AJ50
42600-5AN10
42600-5A410
42600-5AN40
42600-5AL20
42600-5AL30
42600-5AM20
42600-5AM30
42600-5AM40
42600-5AM50
42600-5AM60
42600-5AM70
42600-5AM90
42600-5AN00
42600-5AN20
42600-5AN30
42600-5AQ20
NOTE: (1) Although the involved vehicles are within the above production period, not all
vehicles in this range were sold in the U.S.
(2) This issue only affects vehicles which are equipped with certain run-flat tires from
a specific tire supplier, assembled to wheels by another supplier using a specific
assembly process. Other Toyota or Lexus vehicles sold in the U.S. are not
equipped with those run-flat tires.
3. Total Number of Vehicles Potentially Involved:
6,296
4. Percentage of Vehicles Estimated to Actually Contain the Defect:
Based on results from non-representative inspections of 1,236 run-flat tires during the
investigation, Toyota estimates that approximately 5% of the involved vehicles may have the
cracked condition in the tire sidewall described in this document. However, whether the cracked
sidewall could lead to tread separation would vary depending on the tire use conditions in each
case.
5. Description of Problem:
The subject vehicles are equipped with run-flat tires with a sidewall reinforcement layer inside
the tire. Due to an improper tire to wheel assembly process at a specific supplier, conducted
prior to vehicle assembly, there is a possibility that a crack could develop on the sidewall
reinforcement layer. This crack could expand over time, leading to abnormal noise and vibration.
Under certain driving conditions (such as highway driving speeds with lower levels of tire
inflation), there is a possibility that portions of the tire tread layer could separate. Tread
separation can cause a reduction of vehicle stability and may increase the risk of a crash.
6. Chronology of Principal Events:
July, 2018
In July 2018, Toyota received a field technical report from the Japan market indicating an
abnormal noise from the right front of a Lexus LS vehicle while driving at low speed. The dealer
inspected the vehicle and found a crack on the inside of the right front tire. The tire was
recovered and investigated by the tire supplier. The supplier found that the sidewall
reinforcement layer on the inside of the tire, which is designed to enable the vehicle to continue
to be driven at reduced speed if the tire loses inflation, had a crack. The tire supplier also
investigated the production record but did not find any abnormality in the tire rubber
characteristics for their production tires.
Because the mileage of the vehicle of the recovered tire was relatively low, Toyota inspected mass
production tires at the supplier where tires are assembled to the wheels. A crack was observed
on the sidewall reinforcement layer on some tires which had been assembled with the wheels.
This inspection also indicated that tires which had not yet been assembled with wheels did not
have any cracks.
Based on the inspection result, Toyota investigated the tire and wheel assembly process at this
supplier. In the investigation, Toyota was informed that the process at this supplier included
pressing the sidewall of the tire after assembly to the wheel in order to provide better riding
comfort. Toyota theorized that this additional pressing process may cause a crack to occur. The
sidewall pressing process was stopped, and tire/wheel assemblies were recovered from vehicles
at the Toyota plant and port locations for inspection.
August, 2018 ~ October, 2018
Toyota inspected these recovered tires. There are three different suppliers that manufacture the
run-flat tires for the current generation LS vehicles. However, cracks were observed only on
tires manufactured by a specific tire supplier.
To further investigate whether the aforementioned additional pressing process could lead to the
observed cracks, Toyota conducted crack duplication tests. Tires manufactured by each supplier
were used for the tests. Cracks were observed only on tires manufactured by the specific
supplier, supporting the findings from the inspection of recovered tires. In addition, run-flat
tires for the previous generation LS model were tested, because these tires had been manufactured
at the same facility. However, no cracks were observed resulting from these tests.
To determine the reason why cracks developed only in tires for the current generation LS
manufactured by the specific supplier, Toyota evaluated stress on the sidewall of each tire during
assembly. As a result of the evaluation, Toyota found that, for the current generation LS tires
from the specific supplier, the stress on the sidewall reinforcement layer during the additional
pressing process exceeded its tensile strength. Tires produced at the other suppliers and tires for
the previous generation LS have a different material elasticity, and the tensile strength is not
exceeded during the pressing process. Based on the results of the above investigations, Toyota
determined that a crack could develop on the sidewall reinforcement layer of the current
generation LS run-flat tires, manufactured by the specific supplier due to an improper tire to wheel
assembly process.
To assess the real world impact of potential sidewall cracking resulting from this tire and process
combination, Toyota conducted durability tests with multiple speed and distance parameters using
cracked tires. Testing was done under the ISO standard for run-flat tires (i.e., test using a travel
distance of 80 km and speed of 80 km/h). An additional test model included a travel distance of
30,000 km and a speed of 60 km/h. No abnormality was found on the tires from these tests. In
addition, a severe, high speed test (at 250 km/h, the maximum speed of LS vehicles) was also
conducted. During this test, a partial separation of the tread layer was observed. To identify
whether a crack could lead to separation of the tread layer, Toyota began to investigate the cause
of the tread separation.
November, 2018 ~ February, 2019
Toyota investigated the tire where the partial tread layer separation was observed when the tire
was tested at maximum speed of LS vehicles and found that the tread separation was caused by
heat.
In additional testing, Toyota measured tire temperature at the inside of tread portion of cracked
tires and non-cracked tires tested at the LS vehicle’s maximum speed of 250 km/h. The testing
showed that the temperature of the cracked tire was over 127 degrees Celsius, which is higher
than the temperature of the non-cracked tire. Toyota theorized that the rigidity of the sidewall
could be reduced due to the crack. If rigidity is reduced, deflection of the sidewall could increase
causing deflection of the tread portion to increase, resulting in higher tire temperatures.
To determine whether tread layer separation could occur under normal vehicle usage, Toyota
conducted additional durability tests of cracked tires at multiple speeds with tire pressure set at a
lower level. As a result of this testing, tread layer separation was not observed. However, tire
temperature increased to over 132 degrees Celsius, which is also higher than the temperatures
observed in tests of non-cracked tires. While tread separation only occurred in the severe, high
speed (250 km/h) testing, Toyota could not eliminate the possibility that tread separation could
occur under other driving conditions (such as during highway driving or lower levels of tire
inflation) based on the observation of higher tire temperatures in the aforementioned testing.
Additionally, while the field data and investigation indicate that customers could experience
noise/vibration from the tires, Toyota could not determine how much prior detectability to the
customer would be present in these cases.
February 21, 2019
Based on the results of the above investigation, Toyota decided to conduct a voluntary safety
recall campaign.
As of February 19, 2019 based on a diligent review of records, Toyota’s best engineering
judgment is that there are 8 Toyota Field Technical Reports and 24 warranty claims that have
been received from U.S. sources that 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 Lexus
dealer. All four tires will be replaced with new ones at no charge if one or more tire(s) are runflat
tire(s) manufactured by the specific tire supplier.
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 will be sent by late April, 2019. 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 February 26, 2019. Copies of dealer
communications will be submitted as they are issued.
10. Manufacturer’s Campaign Number:
KLCTECHNICAL INSTRUCTIONS
FOR
SAFETY RECALL KLC
POSSIBLE PARTIAL TREAD SEPARATION OF RUN-FLAT TIRES
CERTAIN 2018 LS 500 & LS 500h
The repair quality of covered vehicles is extremely important to Lexus. All dealership technicians performing this recall 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 recall repair are required to currently hold at least one of the following certification levels:
• Certified
• Senior
• Master
It is the dealership’s responsibility to select technicians with the above certification level or greater to perform this recall 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.
2
I. OPERATION FLOW CHART
Campaign completed, return
the vehicle to the customer
Verify Vehicle Eligibility
1. Check the TIS Vehicle Inquiry System
Not Covered No further action required
Is the vehicle equipped with at
least 1 Bridgestone Turanza
tire of an OE size?
Yes
Replace all 4 tires
No..
Conduct Customer Inquiry to
determine the status of the OE Tires
OE tires are not in
the customers possession
Customer can return
With OE tires
II. IDENTIFICATION OF AFFECTED VEHICLES
• Check the TIS Vehicle Inquiry System to confirm the VIN is involved in this Safety Recall,
and that it has not already been completed prior to dealer shipment or by another dealer.
• TMS warranty will not reimburse dealers for repairs completed on vehicles that are not
affected or were completed by another dealer.
III. PREPARATION
A. PARTS
Tire Size Part Number Quantity Source
245/45RF20 42652-50C90
4 total
(Size may be different from
front to rear)
Tires will be ordered
through Dealer Tire
275/40RF20 42652-50D00
245/45RF20 42652-11070
275/40RF20 42652-11080
245/50RF19 42652-50D50
Part Number Part Description Quantity
04423-33060 Fitting Kit, Tire Pressure Monitor or Balancer Valve 4
3
B. TOOLS & EQUIPMENT
• Standard Hand Tools • Torque Wrench • Tire Mounting Machine
• Tire Balancer • Electric drill • Drill bit: 3/8” or larger
IV. BACKGROUND
The involved vehicles are equipped with run-flat tires that were assembled to the wheels
improperly. There is a possibility that a crack could develop on the sidewall reinforcement layer
of the tires. Under certain driving conditions, portions of the tire tread layer could separate,
causing a reduction of vehicle stability and increasing the risk of a crash.
4
V. WORK PROCEDURE
1. INSPECT THE TIRE BRAND AND MODEL
a. Inspect the brand and model of all 4 tires on the vehicle.
Does the vehicle have any
Bridgestone Turanza tires installed?
Proceed to Step 3. CONFIRM
TIRE SIZE on p.5
Proceed to Step 2 CUSTOMER
INQUIRYon p.4
..YES.. ..No..
Note: It is not possible to distinguish between the Original Equipment Bridgestone Turanza
tires and Bridgestone Turanza replacement tires as bought in the aftermarket. Therefore, any
Bridgestone Turanza tire on an effected vehicle, matching the requirements, should be
replaced. Be sure to replace all 4 tires, even if only 1 tire was an OE Bridgestone Turanza.
If the OE Bridgestone Turanza tires were removed from the vehicle
with useable tread remaining, it’s critical that the OE tires are located
and destroyed to prevent their installation onto a different vehicle.
2. CUSTOMER INQUIRY
If the customers vehicle does not have Original Equipment (OE) Bridgestone Turanza tires
mounted, it will be necessary to question the customer to determine the status of these tires.
Consider the following points when talking with the customer:
• The customer may have snow tires mounted on the vehicle. If so, request the customer to
bring the OE Bridgestone Turanza tires into the dealership for replacement.
• The OE Bridgestone Turanza tires may have worn out and been replaced with a different
brand or incorrect size tire. If so, no tire replacement will be necessary. An Warranty
Operation Code is available for an inspection only, and will close the campaign when used.
• If even 1 tire on the vehicle meets the replacement requirement, all 4 tires will be replaced.
5
3. CONFIRM TIRE SIZE
a. Inspect the size of all 4 tires to confirm they match one of the OE tire size sets:
• Front & Rear: 245/50RF19
• Front & Rear: 245/45/RF20
• Front: 245/45RF20 Rear: 275/40RF20
Do the tire sizes match those
of the OE tire sizes?
Proceed to Step 4 REPLACE
TIRES on p.5
Proceed to Step 2 CUSTOMER
INQUIRY on p.4 to determine
the location of the OE tires
YES No
4. REPLACE TIRES
a. Replace all tires on the vehicle that meet the standards detailed above, being sure to order
the NEW Bridgestone Turanza tires in the same sizes as originally equipped on the vehicle.
b. Install a NEW Tire Pressure Monitor fitting kit.
c. Adjust the air pressure to the standard indicated on the sticker inside the driver’s door jamb.
d. Torque the wheel lug nuts:
Torque: 140 N∙m (1428 kgf∙cm, 103 ft.lbs)
5. DISPOSAL OF ORIGINAL TIRES
It is CRITICAL that the original tires are not reused on a
different vehicle. BE SURE to follow the steps detailed below to
ensure the OE Bridgestone Turanza tires cannot be reused.
a. Using a drill and drill bit of 3/8” or larger, drill a hole in the sidewall of the tire.
b. Dispose of the OE tires in accordance with all local and federal regulations.
6
◄ VERIFY REPAIR QUALITY ►
• Verify that tire pressure are set correctly.
• Verify that wheel lug nut torque is correct.
• Confirm that the Tire Pressure Monitoring System (TPMS) is displaying the tire
pressures correctly.
• Verify that the OE Bridgestone Turanza tires have been properly destroyed and
disposed of in accordance with all local the federal regulations.
If you have any questions regarding this update, please contact your area representative.
10. APPENDIX
A. PARTS DISPOSAL
As required by Federal Regulations, please make sure all recalled parts (original parts)
removed from the vehicle are disposed of in a manner in which they will not be reused,
unless requested for parts recovery return.
B. CAMPAIGN DESIGNATION DECORDER
H 0 A
Year Campaign is Launched
B = 2011
C = 2012
D = 2013
E = 2014
F = 2015
G = 2016
H = 2017
Etc…
Repair Phase
1st Campaign = A
2nd Campaign = B
3rd Campaign = C
4th Campaign = D
5th Campaign = E
27th Campaign = 1
28th Campaign = 2
Etc…
Current Campaign Letter
for this year
0 = Remedy
1 = Interim (Remedy not yet
available) will change to
when the Remedy is available
(May use other characters in
unique cases)
Examples:
C1B = Launched in 2012, Interim Phase, 2nd Campaign Launched in 2012
E0A = Launched in 2014, Remedy Phase, 1st Campaign Launched in 2014
H0A = Launched in 2017, Remedy Phase, 1st Campaign Launched in 2017.
This notice applies to your vehicle:
VIN ABCDEFGH987654321
Spanish translation on back side
KLC Remedy Traducción en español en el lado inverso
URGENT SAFETY RECALL
This is an important Safety Recall.
The remedy will be performed
FREE OF CHARGE to you.
Lexus Division
Toyota Motor Sales, U.S.A., Inc.
6565 Headquarters Drive
Plano, TX 75024
(469) 292-4000
IMPORTANT SAFETY RECALL (Remedy Notice)
Certain 2018 Model Year LS 500 and LS 500h Vehicles
Possible Partial Tread Separation of Run-Flat Tires
NHTSA Recall No. 19V-134
Dear <FirsName/LastName>:
This notice is sent to you in accordance with the National Traffic and Motor
Vehicle Safety Act. Lexus has decided that a defect, which relates to motor
vehicle safety, eexists in certain 2018 Model Year LS 500/500h vehicles.
You received this notice because our records, which are based primarily
on state registration and title data, indicate that you are the current owner.
What is the condition?
The involved vehicles are equipped with run-flat tires that were
assembled to the wheels improperly. There is a possibility that a
crack could develop on the sidewall reinforcement layer of the tires.
Under certain driving conditions, portions of the tire tread
layer could separate, causing a reduction of vehicle stability
and increasing the risk of a crash.
What will Lexus do?
Any authorized Lexus dealer will replace all four tires FREE OF CHARGE, if one or more tires are run-flat tires and the tires are manufactured by
a specific tire supplier.
This is an important Safety Recall.
The remedy will take approximately three hours. However, depending on the dealer’s work schedule, it may be necessary to make your vehicle
available for a longer period of time.
If the vehicle is experiencing the condition described above or if you are uncomfortable driving the vehicle to the dealership, please contact your
local authorized Lexus dealer who will arrange for vehicle pick up.
What if you are not the owner or operator of this vehicle?
If you are a vehicle lessor, Federal Law requires that any vehicle lessor receiving this recall notice must forward a copy of this notice to the
lessee within ten days.
If you know the current owner or operator, please forward this letter to them.
If you would like to update your vehicle ownership or contact information, you may do so by registering at https://drivers.lexus.com/lexusdrivers.
You will need your full 17-digit Vehicle Identification Number (VIN) to input the new information.
If you believe that the dealer or Lexus has failed or is unable to remedy the defect within a reasonable time or without charge, you may submit
a complaint to the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey Avenue S.E., Washington, D.C. 20590, or
call the toll free Vehicle Safety Hot Line at 1-888-327-4236 (TTY: 1-800-424-9153), or go to https://www.safercar.gov.
We have sent this notice in the interest of your continued satisfaction with our products. We sincerely regret any inconvenience this condition may have
caused you.
Thank you for driving a Lexus.
Sincerely,
Lexus, A Division of Toyota Motor Sales, USA
What Should You Do?
3 Please contact any authorized Lexus dealer to schedule
an appointment to have the remedy performed as soon
as possible. Your local Lexus dealer will be more than
happy to answer any of your questions.
3 To find a dealer near you, visit www.lexus.com/dealers.
3 For more information on this and other Safety Recalls, including
Frequently Asked Questions, visit www.lexus.com/recall.
Input your full 17-digit Vehicle Identification Number (VIN)
noted above to review information specific to your vehicle.
3 I f you require fur ther ass i s tance, please visit
https://Lexus.com/contact for options to contact the
Lexus Guest Experience Center.
Lexus Division
Toyota Motor Sales, U.S.A., Inc.
6565 Headquarters Drive
Plano, TX 75024
(469) 292-4000
KLC Remedy
RETIRO DE SEGURIDAD URGENTE
Este es un Retiro de Seguridad importante.
La reparación se efectuara
SIN CARGOpara usted.
English version on front side
Versión en inglés en el frente
Este aviso aplica a su vehículo:
VIN ABCDEFGH987654321
IMPORTANTE RETIRO DE SEGURIDAD (Aviso de Remedio)
Ciertos vehículos modelo LS 500 y LS 500h del año 2018
Posible separación parcial de la banda de rodamiento de los neumáticos de rodamiento sin aire
No. de retiro de NHTSA 19V-134
Estimado (nombre/apellido del cliente):
Esta notificación se le envía de acuerdo con los requisitos establecidos en
el Acta de Tráfico Nacional y de Seguridad de Vehículos Motorizados.
ha decidido que existe un defecto relacionado con la seguridad de los
vehículos motorizados en ciertos vehículos modelo LS 500/500h
específicos del año 2018.
Usted recibió este aviso porque nuestros registros, basados
principalmente en la información de registro y titularidad estatal,
indican que usted es el propietario actual.
¿Cuál es la condición?
Los vehículos afectados están equipados con neumáticos de
rodamiento sin aire que se ensamblaron en las llantas de forma
incorrecta. Existe la posibilidad de que se forme una grieta en la capa
de refuerzo del lado de la llanta de los neumáticos. En ciertas
condiciones de conducción, porciones de la capa de la
banda de rodadura del neumático podrían separarse,
causando una reducción de la estabilidad del vehículo y
aumentando el riesgo de colisión.
¿Qué hará Lexus?
Cualquier concesionario Lexus autorizado reemplazará los cuatro neumáticos SIN CARGO para usted , si al menos uno de ellos es un
neumático de rodamiento sin aire y está fabricado por un proveedor de neumáticos específico.
Este es un Retiro de Seguridad importante.
La reparación tomará aproximadamente tres horas. Sin embargo, dependiendo del horario de trabajo del concesionario, es posible que necesiten
su vehículo por más tiempo.
Si el vehículo está experimentando la condición descrita y usted no se siente cómodo conduciendo el vehículo hasta el concesionario, contacte
con su concesionario Lexus autorizado local para que dispongan la recogida del vehículo.
¿Qué sucede si usted no es el propietario o usuario de este vehículo?
Si usted es arrendador del vehículo, la Ley Federal exige que toda persona que arrienda vehículos y reciba este aviso de retiro de seguridad
envíe una copia del mismo al arrendatario dentro de los diez días.
Si conoce al propietario o usuario actual del vehículo, por favor, reenvíeles esta carta.
Si desea actualizar la información de propiedad de su vehículo o de contacto, puede hacerlo registrándose en
https://drivers.lexus.com/lexusdrivers. Necesitará su Número de Identificación del Vehículo (VIN) de 17 dígitos para ingresar la nueva información.
Si considera que el concesionario o Lexus no han logrado o no pueden solucionar el defecto dentro de un plazo razonable o sin cargo para
usted, puede presentar una queja al Administrador, a la National Highway Traffic Safety Administration [Administración Nacional de Seguridad
Vial en Autopistas], 1200 New Jersey Avenue S.E., Washington, DC 20590, o llame sin costo a la línea directa de Seguridad Automotor al
1-888-327-4236 (TTY: 1-800-424-9153), o visite https://www.safercar.gov.
Hemos enviado este aviso porque estamos interesados en su constante satisfacción con nuestros productos. Lamentamos sinceramente cualquier
inconveniente que esta condición le haya podido causar.
Gracias por conducir un Lexus.
Atentamente,
Lexus, A Division of Toyota Motor Sales, USA
¿Qué Debe Hacer Usted?
3 Por favor, póngase en contacto con cualquier
concesionario Lexus autorizado para concertar una
cita a fin de realizar esta reparación lo antes posible.
Su concesionario Lexus local responderá con gusto a
todas sus preguntas.
3 Para encontrar su concesionario más cercano, visite
www.lexus.com/dealers.
3 Para más información acerca de este retiro de seguridad y
otros, incluidas las preguntas más frecuentes, visite
www.lexus.com/recall. Ingrese su Número de Identificación del
Vehículo (VIN) de 17 dígitos que aparece en la parte superior
para revisar la información específica a su vehículo.
3 Si necesita más asistencia, visite https://Lexus.com/contact para
ver las opciones disponibles para contactar con el Centro de
Experiencia del Cliente de Lexus.
SEOCONTENT-END