2018-2021 Toyota Tundra SAFETY RECALL 21TA06 Potential Increased Risk of Vehicle Fire

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Headlight Electrical Connector May Overheat

An overheated electrical connector can increase the risk of a fire.

 

NHTSA Campaign Number: 21V688

Manufacturer Toyota Motor Engineering & Manufacturing

Components ELECTRICAL SYSTEM, EXTERIOR LIGHTING

Potential Number of Units Affected 158,489

 

Summary

Toyota Motor Engineering & Manufacturing (Toyota) is recalling certain 2018-2021 Tundra vehicles. The headlight electrical circuits may power the high and low beams simultaneously, which could overheat the electrical connector.

 

Remedy

Dealers will modify the engine wire harness assembly and replace any damaged bulb, bulb connector, and/or headlight assembly as necessary, free of charge. Owner notification letters were mailed April 25, 2022. Owners may contact Toyota customer service at 1-800-331-4331. Toyota’s numbers for this recall are 21TB06 and 21TA06.

 

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

 


On September 2, 2021 Toyota filed a Defect Information Report (DIR) with the National Highway Traffic Safety Administration (NHTSA) informing the agency of our intent to conduct a voluntary Safety Recall on certain 2018 – 2021 model year Tundra vehicles.

 

Condition

The subject vehicles are equipped with halogen headlamps that allow the circuits for both the high and low beam bulb filaments to be energized at the same time when the high beams are switched on. Under some conditions, if the high beams are repeatedly left on for an extended period while the vehicle is idling or driving at low speed, there is a possibility that the bulb connector could overheat to a level that can result in an increased risk of a fire that can propagate to other parts of the vehicle.

 

Remedy

Toyota dealers will modify the engine wire harness assembly and inspect the headlight bulb connector, bulb, and headlight assembly. If one or more of these components is found to be damaged due to this overheating condition, the damaged component(s) will be replaced with new ones as needed.

Important Note: The dates specified in this table are estimates and are subject to change.

 

Covered Vehicles

There are approximately 158,500 vehicles covered by this Safety Recall. Approximately 300 vehicles involved in this Safety Recall were distributed to Puerto Rico.

 

Owner Letter Mailing Date (Interim)

Phase 1 mailing will start late April and continue over several weeks.

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.

 

New Vehicles in Dealership Inventory 

There are approximately 10 vehicles in new dealer inventory as of September 1, 2021.

 

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

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 21TA06” and include the VIN.

NOTE: Dealers can identify if any of their new and used inventory has any open campaigns in the Vehicle Inventory Summary available in Dealer Daily (Non SET and GST dealers: https://dealerdaily.toyota.com/). The Vehicle Inventory Summary may take up to 4 hours to populate information for newly launched campaigns.

 

Toyota Certified Used Vehicle (TCUV)

The TCUV policy prohibits the certification of any vehicle with an outstanding Safety Recall, Special Service Campaign, or Limited Service Campaign. Thus, no affected units are to be designated, sold, or delivered as a TCUV until all applicable Safety Recalls, Special Service Campaigns, and Limited Service Campaigns have been completed on that vehicle.

 

Toyota Rent-A-Car (TRAC) & Service Loaners

Toyota requests that dealers remove all TRAC and Service Loaner vehicles from service that are covered by a Safety Recall unless the defect has been remedied.

 

Customer Contacts

Customers who receive the owner letter may contact your dealership with questions regarding the letter and/or the Safety Recall. Please welcome them to your dealership and answer any questions that they may have. A Q&A is provided to assure a consistent message is communicated.

Customers with additional questions or concerns are asked to please contact the Toyota Brand Engagement Center (1-888-2709371) – Monday through Friday, 8:00 am to 8:00 pm, Saturday 9:00 am to 7:00 pm Eastern Time.

 

Head Unit Notifications

Head unit notifications are electronic messages that are displayed in the vehicle’s audio system screen. Customers who receive head unit notification regarding this Safety Recall are requested to schedule an appointment with their authorized dealer to have this Safety Recall completed.

When these messages are received by the vehicle’s Data Communication Module, the head unit will display a pop-up prompt stating that the vehicle has a new Safety Recall. The prompt will contain options to ‘Snooze’ or to ‘View’ the message. If a customer chooses ‘Snooze’, the message will continue to reappear every 20 minutes until the customer chooses ‘View’. If a customer views and then closes the message, the message will be available in the Notification App if the customer chooses to review it again. If the vehicle’s completion status remains incomplete for a period of 90 days from the message being viewed, the head unit may display a renotification pop-up prompt as an additional reminder to the customer to have this Safety Recall completed.

The message will completely clear from the vehicle once the following conditions are met: The Safety Recall is completed, the dealer has filed a claim, and the claim is approved by Toyota. Then the message will be cleared at the next clearing cycle, which currently happens weekly.

Owners who receive a head unit notification after having this Safety Recall completed can be advised to ignore the message. Owners with additional concerns can be directed to the Toyota Brand Engagement Center (1-888-270-9371) – Monday through Friday, 8:00 am to 8:00 pm, Saturday 9:00 am to 7:00 pm Eastern Time.

 

Salvage Title Vehicles

Every attempt should be made to complete an open Safety Recall when circumstances permit, unless noted otherwise in the Safety Recall dealer letter.

For complete details on this policy, refer to Toyota Warranty Policy 4.17, “What Is Not Covered by The Toyota New Vehicle Limited Warranty”.

 

Media Contacts

It is imperative that all media contacts (local and national) receive a consistent message. In this regard, all media contacts must be directed to Aaron Fowles (469) 292-1097 in Toyota Corporate Communications. Please do not provide this number to customers. Please provide this contact only to media.

 

Parts

Part Number Description Quantity
04001-2410C Wire, Engine Room Main Repair Kit* 1

 

The following parts are only needed based on inspection and if damage is found; it is anticipated that very few vehicles will require these parts. 

Part Number Description Quantity (As needed)
04001-2610C Connector, Repair Kit 1*
90084-98033 Bulb 2**
81150-0C130 Headlight Assembly RH 1**
81110-0C130 Headlight Assembly LH 1**


** Headlamp Assembly comes with bulb preinstalled, no need to order bulbs if replaced.

 

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.

 

Customer Reimbursement 

Reimbursement consideration instructions will be included in the owner letter.

 


Fire Frequently Asked Questions

Original Publication Date: September 2, 2021

 

Q1: What is the condition?

The subject vehicles are equipped with halogen headlamps that allow the circuits for both the high and low beam bulb filaments to be energized at the same time when the high beams are switched on. Under some conditions, if the high beams are repeatedly left on for an extended period while the vehicle is idling or driving at low speed, there is a possibility that the bulb connector could overheat to a level that can result in an increased risk of a fire that can propagate to other parts of the vehicle.

 

Q1a: Are there any warnings that this condition exists?

Yes, customer may see smoke from the headlight assembly.

 

Q1b: Is there anything I can do to avoid this condition before the recall remedy is applied?

Until the remedy is performed, avoid repeatedly leaving on the high beams while stationary or driving at low speeds for extended periods of time (for example, multiple hours). During these situations, use the low beam if it is safe to do so.

 

Q2: What is Toyota going to do?

Toyota dealers will modify the engine wire harness assembly and inspect the headlight bulb connector, bulb, and headlight assembly. If one or more of these components is found to be damaged due to this overheating condition, the damaged component(s) will be replaced with new ones as needed.

 

Q3: Which and how many vehicles are covered by this Safety Recall?

There are approximately 158,500 vehicles covered by this Safety Recall.

Model Name Model Year Production Period
Tundra 2018-2021 Early June 2017 – Late March 2021

Note: Only Tundra vehicles manufactured in the production period above and equipped with halogen headlamps are involved in this safety recall.  Tundra vehicles equipped with LED headlamps are NOT involved in this safety recall.

 

Q4: How long will the repair take?

The repair takes approximately 3 and a half hours. However, depending upon the dealer’s work schedule, it may be necessary to make the vehicle available for a longer period of time.

 

Q5: What if I previously paid for repairs related to this Safety Recall?

Reimbursement consideration instructions will be provided in the owner letter.

 

Q6: How does Toyota obtain my mailing information?

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?

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.

 


Description of Problem:

The subject vehicles are equipped with halogen headlamp electrical circuits that were designed incorrectly to allow the circuits for both the high and low beam bulb filaments to be energized simultaneously when the high beams are switched on.  If the high beams are subjected to repeated extended use (e.g., continuously switched “on” in a commercial setting when the vehicle is idling or driving at low speed for extended periods of time and not allowing air flow to cool the headlamp connector), excess heat over multiple days could lead to degradation of the bulb insulation and eventually the bulb connector.  This can cause an open headlamp circuit, leading to an inoperative headlamp that can be noticed by the driver and repaired.  However, if an open circuit does not occur, there is a possibility that the connector could continue to overheat, resulting in an increased risk of a fire that may propagate to other parts of the vehicle.

 

Chronology of Principal Events:

April 2020 – September 2020

In early April 2020, Toyota received the first field report alleging a thermal event at the headlamp connector on a subject vehicle.  The report alleged the headlamp caught on fire.  Toyota inspected the vehicle and observed a melted headlamp assembly and headlamp connector.  However, the damage did not appear to propagate beyond the headlamp assembly.  The parts were recovered and were sent to the respective suppliers for investigation.  The bulb supplier investigated the internal structure of the bulb and could not identify any interior shorts or abnormalities within the bulb.  The wire harness supplier investigated the recovered parts and observed that the wire harness had been damaged but could not determine what may have caused the damage or if it was related to the allegation.  Based on the investigation described above of the recovered parts, the suppliers reported that the aforementioned thermal event was not caused by a manufacturing defect, but were unable to determine the cause of the thermal event.

 

October 2020 – December 2020

By October, Toyota had received multiple field reports, a majority of which alleged an inoperative bulb and/or a melted headlamp connector; a few alleged a flame at the headlamp assembly.  A number of the reports were for commercially used fleet vehicles in Midland, Texas.  Toyota hypothesized that there may be unique road conditions or customer usage conditions, so Toyota undertook a field investigation in Midland to conduct various tests on headlamps of customer and Toyota fleet vehicles, including temperature evaluations.  Toyota surveyed some of these customers’ driving patterns and conducted duplication testing.  During that testing (i.e., following the drive patterns described during the customer surveys which included parking the vehicle with the high beams illuminated for extended periods of time (~1 hour)), Toyota observed that, after approximately 30 minutes of idling the vehicle with the high beams turned on, the temperature of the connector exceeded the maximum design specification temperature of the headlamp connector.  At this point, it was unknown what was causing this to occur.

 

In November, Toyota requested the supplier to conduct duplication testing (i.e., 8 hours per day, daily, for less than 1 week) on the headlamp assembly to attempt to match the observations from the aforementioned field investigation.  During duplication testing, initially the test results did not match the field investigation observation of an abnormal rise in temperature of the headlamp connector in approximately 30 minutes.  After Toyota reviewed the supplier’s test set up, it was observed that the set up only energized either the high or low beams but not both.  After a further review of the previously collected field investigation information, it was observed that this supplier test did not match what was observed in the field because, in those field cases, when the high beams were illuminated, both high and low beams were energized and simultaneously illuminated.  Toyota requested the supplier to re-run the tests (this time, 8 hours per day, daily, for approximately 2 – 3 weeks) with both the high and low beams energized.  As a result of the additional testing, it was observed that the connector temperature did increase and some minor melting damage to the connector occurred, but it did not result in a flame.  Toyota reviewed the headlamp specification and determined that the specification was incorrect as the high and low beam circuits for halogen head lamps should not be simultaneously energized.

 

January 2021 – March 2021

At this point, it appeared that the incorrect wiring specification may be contributing to the inoperative headlamp allegations.  However, supplier testing thus far had only observed increased temperatures and minor melting damage.  Additional testing for more extended periods of time was needed to determine whether the condition resulting from this incorrect wiring specification could produce a flame that could propagate to other areas of the vehicle.   As a result, Toyota began a series of studies to understand the other customers use cases which led to the reports of inoperative headlamps and/or melted connectors or alleged flame at the headlamp assembly occurring in the subject vehicles.  As a result of these studies, Toyota was able to identify that some customers were using their high beams for extended periods of time during idle or very slow-moving conditions.  Toyota used this new information for additional duplication testing to understand the contributing factors for the aforementioned conditions and to understand the possibility of any flame at the headlamp assembly to propagate outside of the assembly.

 

April 2021 – August 2021

In mid-April Toyota began duplication testing using a bench test with the headlamp assembly and the wire harness connector to determine if a flame could be produced from prolonged activation of the high and low beam circuits under conditions modeling the aforementioned information.  Toyota energized the bulbs in both the high and low beams for 8 hours per day.  During the following 30 business days, Toyota observed the maximum temperature of the bulb and the connector incrementally increased daily.

 

In June, on the 31st business day of testing a flame was produced at the headlamp connector; however, during this first test, the flame was extinguished.  Toyota sent some of the test parts to the supplier for evaluation and continued the testing for the additional test pieces.

 

Toyota continued the aforementioned testing and was unable to produce another flame in the headlamp assembly with the additional test pieces.  As Toyota could not create another flame to observe any potential propagation to the headlamp assembly, Toyota decided to conduct a different test by introducing a flame onto the headlamp connector in order to observe potential propagation within the headlamp assembly.  Toyota was able to observe that a flame which begins at the headlamp connector could propagate through the headlamp assembly.

 

August 27, 2021

Although this testing was conducted using only the headlamp assembly and connector,

Toyota’s engineering judgement based on the flame propagation was that it was possible for the flame to spread to other parts of the vehicle (e.g., front fender, hood, etc.).  Based on the results of the above investigation, Toyota decided, out of an abundance of caution, to conduct a voluntary safety recall campaign.

 

As of August 24, 2021, based on a diligent review of records, Toyota’s best engineering judgement is that there are 18 Toyota Field Technical Reports dated between April 2, 2020 and April 22, 2021 (12 alleging an inoperative headlamp and/or damage to the headlamp connector (e.g., connectors melting), but no apparent flame, and 6 alleging a flame at the headlamp assembly) and 47 warranty claims dated between July 31, 2018 and July 21, 2021 (44 alleging an inoperative headlamp and/or damage to the headlamp connector (e.g., connectors melting), but no apparent flame, and 3 alleging a flame at the headlamp assembly) 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:

For all involved vehicles, Toyota dealers will modify the engine wire harness assembly and inspect the headlight bulb connector, bulb, and headlight assembly. If one or more of these components is found to be damaged due to this overheating condition, the damaged component(s) will be replaced with new ones as needed.

 

Reimbursement Plan for pre-notification remedies

The owner letter will instruct vehicle owners who have paid to have this condition remedied prior to this campaign to seek reimbursement pursuant to Toyota’s General Reimbursement Plan.

 

Recall Schedule:

Notifications to owners of the affected vehicles will occur by November 1, 2021.  A copy of the draft owner notification will be submitted as soon as it is available.

 

Distributor/Dealer Notification Schedule:

Notifications to distributors/dealers will be sent on September 2, 2021.  Copies of dealer communications will be submitted as they are issued.

 

Manufacturer’s Campaign Number:

[Interim / Remedy] 21TB06 / 21TA06

 


4 Affected Products

Vehicle

MAKE MODEL YEAR
TOYOTA TUNDRA 2018-2021

 


11 Associated Documents

Defect Notice 573 Report

RCLRPT-21V688-3368.PDF 216.257KB

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Recall Acknowledgement

RCAK-21V688-1899.pdf 645.638KB

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September 2, 2021 DEFECT INFORMATION REPORT

RMISC-21V688-1558.pdf 87.971KB

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Manufacturer Notices(to Dealers,etc) – 21TB06 Dealer Package Published 9.2.21

RCMN-21V688-9434.pdf 416.12KB

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Manufacturer Notices(to Dealers,etc) – Toyota 12/16/2021 The attached FAQ has an update for remedy timing

RCMN-21V688-5348.pdf 493.303KB

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Recall 573 Report-Amendment 1

RCLRPT-21V688-6470.PDF 216.263KB

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September 16, 2021 AMENDED DEFECT INFORMATION REPORT

RMISC-21V688-0584.pdf 169.986KB

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ISSUED Interim Owner Notification Letter(Part 577)

RIONL-21V688-2579.pdf 359.662KB

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Recall 573 Report-Amendment 2

RCLRPT-21V688-3864.PDF 216.388KB

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Manufacturer Notices(to Dealers,etc) – Toyota Date: September 2, 2021 SAFETY RECALL 21TA06 (Remedy Notice)

RCMN-21V688-3279.pdf 479.561KB

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ISSUED Owner Notification Letter(Part 577)

RCONL-21V688-0726.pdf 359.409KB

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Latest Recalls Documents

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=21V688&docType=RCL

 


 

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