21TA09 Possible Sudden Loss of Braking Assist – 2018-2019 Toyota Camry

November 17, 2021 NHTSA CAMPAIGN NUMBER: 21V890000

Possible Sudden Loss of Braking Assist

A sudden loss of braking assist can increase the risk of a crash.

 

NHTSA Campaign Number: 21V890

Manufacturer Toyota Motor Engineering & Manufacturing

Components SERVICE BRAKES, HYDRAULIC

Potential Number of Units Affected 227,490

 

Summary

Toyota Motor Engineering & Manufacturing (Toyota) is recalling certain 2018-2019 Camry vehicles. The vane cap inside the vacuum pump may break, causing the pump to fail, which could result in a sudden loss of braking assist.

 

Remedy

Dealers will repair or replace the vacuum pump, as necessary, free of charge. Owner notification letters were mailed May 16, 2022. Owners may contact Toyota customer service at 1-800-331-4331.

 

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

 


Certain 2018-2019 Model Year Camry
Sudden Loss of Power Braking Assist May Occur
NHTSA Recall No. 21V-890

Model / Years Production Period Approximate Total Vehicles Approximate Stop Sale Dealer Inventory
2018-2019 Camrymid-January 2017 to mid September 2018227,4900

On November 17, 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 2018-2019 model year Camry vehicles.

 

Condition

The subject vehicles have a system that provides power brake assist when the driver depresses the brake pedal.  Specific components in a part of this system can prematurely wear and could lead to a sudden loss of power braking assist.  Non-power assisted braking will remain functional.  However, a sudden loss of power braking assist while driving could increase the risk of a crash.

 

Remedy

Any authorized Toyota dealer will inspect the vacuum pump assembly and repair or replace it, FREE OF CHARGE.  In the rare case that the condition has occurred at the time of inspection, the Toyota dealer will repair or replace any other damaged parts caused by the condition, FREE OF CHARGE.

 

Covered Vehicles

There are approximately 227,490 vehicles covered by this Safety Recall. Approximately 349 vehicles involved in this Safety Recall were distributed to Puerto Rico.

 

Owner Letter Mailing Date

Toyota will begin to notify owners about the remedy in mid-May 2022. A sample of the owner notification letter has been included for your reference.

 

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 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 – Reminder  

Toyota has not identified any new vehicles in dealership inventory that are covered by this Safety Recall. However, below is a reminder of the dealer’s obligations pertaining to Safety Recalls if there are new vehicles in dealership inventory:

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.

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: 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.

 

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 21TA09/21TB09” 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.

 

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.

 

Loaner Vehicle or Alternative Transportation Reimbursement Procedure

If a customer was uncomfortable driving their vehicle during the interim phase when the remedy was unavailable, a loaner vehicle or alternative transportation through Toyota Rent-A-Car (TRAC) can be claimed for $42 per day.

 

Customer Reimbursement 

Reimbursement consideration instructions will be included in the owner letter.

 


Frequently Asked Questions
Original Publication Date: May 5, 2022

 

Q1: What is the condition?

The subject vehicles have a system that provides power brake assist when the driver depresses the brake pedal.  Specific components in a part of this system can prematurely wear and could lead to a sudden loss of power braking assist. Non-power assisted braking will remain functional.  However, a sudden loss of power braking assist while driving could increase the risk of a crash.

 

Q1a: Are there any warnings that this condition exists?

No. However, if the condition occurs, the driver may observe increased brake pedal effort, warning light illumination and/or an audible chime.

NOTE: It is possible for the warning lights above to be illuminated and the condition not be related to this safety recall.

Q1b: What should I do if my vehicle presents the condition?

A1b: If increased brake pedal effort, warning light illumination and/or audible chimes are observed, the driver should pull over and stop the vehicle in a safe area at the earliest opportunity. The driver should then contact his/her local Toyota dealer for assistance.

 

Q2: What is Toyota going to do?

Toyota will send an owner notification by first class mail starting in mid-May, 2022 advising owners to make an appointment with their authorized Toyota dealer.  The Toyota dealer will inspect the vacuum pump assembly and repair or replace it, FREE OF CHARGE.  In the rare case that the condition has occurred at the time of inspection, the Toyota dealer will repair or replace any other damaged parts caused by the condition, FREE OF CHARGE.

 

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

There are approximately 227,490 vehicles covered by this Safety Recall.

Model Name Model Year Production Period
Camry2018-2019Mid-January 2017 to mid-September 2018

 

Q4: How long will the repair take?

The repair takes approximately one hour in most cases.  However, depending upon the dealer’s work schedule, it may be necessary to make the vehicle available for a longer period of time.  In the rare case that the condition has occurred, the repair may take longer depending on which other parts were damaged by the condition. Your dealer can advise you on the expected repair time for the additional repairs based on the vehicles condition.

 

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 use a specific mechanical vacuum pump and a brake booster to provide power brake assist to the driver.  This vacuum pump contains a vane that rotates inside the pump body to supply vacuum to the brake booster.  A cap on each end of the vane helps the vane maintain contact with the pump body as it rotates.  Due to the material of these caps, the caps may prematurely wear when the vehicle is operated under certain driving conditions such as frequent braking and/or long periods of idling.  After sufficient wear, a cap can become stuck between the vane and the pump housing, breaking it, and potentially breaking other components inside and/or connected to the pump.  If this occurs, the vacuum pump would no longer supply vacuum to the brake booster.  Continued application of the service brakes thereafter can deplete the amount of brake assist remaining in the brake booster.  The driver may observe increased braking effort and an audible and visual warning.  While the service brakes remain operational with a broken vane cap, depending on the brake application by the driver, brake performance could be suddenly reduced prior to any warnings.  A sudden loss of braking assist while driving could increase the risk of a crash.

 

Chronology of Principal Events:

September 2019 – June 2020

In late September 2019, Toyota received a report from a dealer in the U.S. market on a 2018MY Toyota Camry equipped with a 4-cylinder A25A engine where it was reported that the brake pedal felt hard and the vehicle was difficult to stop.  The field report indicated that no DTC was observed, but the vacuum pump gear had seized, and the end of the exhaust camshaft had broken off.  Toyota recovered the parts and sent them to the supplier in Japan for further inspection and evaluation.  From the part inspection, it was observed that a piece of the vane cap had broken off and was found lodged between the vane and the pump body.

After further evaluation with the supplier, signs of wear were observed on the vane cap at the location where it contacts the vane inside the vacuum pump.  (Vane cap wear is not unexpected during normal operation of the vacuum pump over time, as the vane cap moves/slides on the vane while rotating inside the vacuum pump; Toyota specifies maintenance inspection(s) for vacuum pump operation.)  Additionally, the supplier reviewed their manufacturing process history and records, and found that there were no manufacturing change points or abnormalities that may have contributed to the premature wear of the vane cap in the field vehicle.  The supplier also reviewed sample parts from the same lot number of the affected vane cap and found no abnormalities in the parts.

By December, Toyota had received four additional reports and continued to recover the parts from those vehicles for inspection and evaluation of the vacuum pumps.  Toyota continued to sporadically receive additional reports and continued to inspect the recovered parts from the field.  After analyzing the additional recovered parts, Toyota identified that the molecular weight of the vane cap was smaller for the recovered parts.  Toyota hypothesized that vane caps from the failed parts may degrade due to the thermal loading, resulting in premature wear during operation.

In April, 2020 Toyota began duplication testing on the vacuum pump operation with high temperatures.  Toyota was investigating the run time versus wear on the vane cap.  By June, the thermal load testing had concluded, and the results of the investigation found that the wear amount on the vane caps did not reach a level that would cause the vane cap to contact the rotor edge inside the vacuum pump or contact the pump body and cause the vane cap breakage.  Toyota was unable to duplicate the condition observed in the parts from the field through this testing.  At this time Toyota believed that thermal loading was not a contributing factor to the premature wear of the vane cap.

 

July 2020- June 2021

In failed vacuum pumps with broken vane caps recovered from the field, Toyota had observed large differences in the wear amounts on the vane caps even for vehicles with similar mileage.  As a result, Toyota began preparations to collect vehicle driving history from vehicles in the field.  Toyota planned to target customers who had previously experienced a failure of the vacuum pump or had previously experienced a vacuum pump replacement.  Unfortunately, due to the lack of availability of the data logging equipment and additional shipping delays, preparation for the activity was unable to be completed until November 2020.  Additionally, due to impacts from COVID-19, Toyota was unable to get some customers to come to the dealers during this period or obtain owner consent to track their driving history.

In December 2020, Toyota began the installation of the data logging equipment into customer vehicles to begin gathering vehicle driving history.  Based on Toyota’s test criteria to understand driving history of these vehicles, it took approximately six months to gather a sufficient amount of driving data necessary for the evaluation.  Due to the aforementioned lack of availability of equipment, Toyota could only gather data from a few customer vehicles at a time.  Each vehicle had to drive for approximately two months in order to obtain a sufficient amount of driving data for analysis.

In June 2021, the collection of customer driving history was nearly complete, and some initial data had been sent for evaluation.  Meanwhile, during a review of other field information, Toyota recognized the broad range of allegations (e.g., noise, warning messages, braking performance issues, pedal feel, etc.) that had been received and that the timing and progression of those indicators was unknown.  As a result, Toyota decided to conduct duplication testing to understand the performance of a worn vane cap on a vehicle.

 

July 2021- October 2021

In July, the driver history data collection had been completed, and the vacuum pumps from those vehicles in the driving study were recovered and sent for evaluation.  Toyota began to analyze the data, looking at various driving conditions in an attempt to understand how much load the vacuum pump was experiencing.

Additionally, in July Toyota started to recover parts to conduct the aforementioned duplication testing.  After a review of the recovered parts, Toyota determined that none of the parts had enough wear to evaluate a potential failure during testing.  As a result, Toyota produced special testing vane caps that had material intentionally removed (machined out) to simulate wear on the vane caps.

In late October, after reviewing the test results and the recovered vehicle driving history data and data modeling, Toyota observed that the vane caps exhibited a larger amount of wear if the vehicle experienced more frequent braking or long periods of engine idling.  Frequent braking and long idling could apply more load on the vane cap than vehicles with less frequent braking or less idling periods, leading to premature wear of the vane cap.  After sufficient wear, a cap can become stuck between the vane and the pump housing, breaking it, and potentially breaking other components inside and/or connected to the pump.  If this occurs, the vacuum pump would no longer supply vacuum to the brake booster.  In addition, broken cap could cause the vane or the connecting portion between the pump rotor and exhaust camshaft to break.  Continued application of the brakes could lead to an illumination of warnings, an audible chime, and can deplete the amount of brake assist remaining in the brake booster.  Depending on the brake application by the driver, brake performance could be suddenly reduced prior to any warnings.  A sudden loss of braking assist while driving could increase the risk of a crash.

 

November 11, 2021

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

As of October 26, 2021 based on a diligent review of records, Toyota’s best engineering judgment is that there is 14 field technical reports (received between October 25, 2019 and October 26, 2021) and 61 unverified warranty claims (received between June 14, 2018 and September 20, 2021) 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 by first class mail to return their vehicles to a Toyota dealer.  For all involved vehicles, Toyota dealers will inspect the vacuum pump and repair or replace it, free of charge to customers.

 

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 January 16, 2022.  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 November 17, 2021.  Copies of dealer communications will be submitted as they are issued.

 

Manufacturer’s Campaign Number:

[Interim / Remedy] 21TB09 / 21TA09

 


Sudden Loss Of Power Braking Assist May Occur – 2018-2019 Toyota Camry

 

 


2 Affected Products

Vehicle

MAKEMODELYEAR
TOYOTACAMRY2018-2019

 


15 Associated Documents

Manufacturer Notices(to Dealers,etc) – Toyota DATE January 12, 2022 TOPIC Interim Rental Op-codes are now available in the dealer letter.

RCMN-21V890-4684.pdf 1080.954KB

 


ISSUED Interim Owner Notification Letter(Part 577)

RIONL-21V890-0075.pdf 418.21KB

 


Manufacturer Notices(to Dealers,etc) – Toyota Date: November 17, 2021 SAFETY RECALL 21TA09 (Interim Notice 21TB09) Certain 2018-2019 Model Year Camry Sudden Loss of Power Braking Assist May Occur

RCMN-21V890-8677.pdf 981.059KB

 


Part 577 Owner Notification Envelope

RONE-21V890-6194.pdf 211.637KB

 


Recall Acknowledgement

RCAK-21V890-7469.pdf 644.912KB

 


Defect Notice 573 Report

RCLRPT-21V890-4129.PDF 214.811KB

 


TOYOTA November 17, 2021 DEFECT INFORMATION REPORT

RMISC-21V890-6517.pdf 106.384KB

 


Manufacturer Notices(to Dealers,etc) – Toyota DATE: April 13, 2022 TOPIC: Additional interim rental Op-codes are available in the dealer letter.

RCMN-21V890-5773.pdf 1070.045KB

 


Remedy Instructions and TSB

RCRIT-21V890-0570.pdf 1815.13KB

 


Manufacturer Notices(to Dealers,etc) – Toyota Date: May 5, 2022 SAFETY RECALL 21TA09 (Remedy Notice)

RCMN-21V890-0663.pdf 1003.523KB

 


Toyota Date: May 5, 2022 SAFETY RECALL 21TA09 (Remedy Notice) **UPDATED Dealer Letter and Technical Instructions Available on TIS**

RMISC-21V890-8814.pdf 150.52KB

 


ISSUED Owner Notification Letter(Part 577)

RCONL-21V890-5333.pdf 418.192KB

 


Manufacturer Notices(to Dealers,etc) – Toyota DATE: May 11, 2022 TOPIC: Interim Rental Op Code has been added to the dealer letter

RCMN-21V890-0138.pdf 1041.825KB

 


Recall Quarterly Report #1, 2022-2

RCLQRT-21V890-7379.PDF 211.165KB

 


Recall Quarterly Report #2, 2022-3

RCLQRT-21V890-6805.PDF 211.275KB

 


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