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2004 Toyota Prius

Owner reports · Recalls · Investigations

More warning signs than most Prius years

Owner complaints for the 2004 Toyota Prius are substantially higher than the model-year median of 164.

About this comparison →

When problems were reported

Mileage at the reported incident

503 reports with mileage · 107 unknown

NHTSA’s mileage field refers to the reported incident, not necessarily the filing date. This shows report counts, not the likelihood of a failure.

What to inspect

Issues worth paying extra attention to based on owner reports.

  • Exterior Lighting. Review the 184 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Electrical System. Review the 177 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Engine And Engine Cooling. Review the 89 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →

NHTSA owner reports · September 18, 2026 snapshot.

38 crash reports2 fire reports21 injury reports

What owners actually said

610 reports
191,800 miles · Oct 26, 2012
Exterior Lighting

WHILE DRIVING MY 2004 TOYOTA PRIUS HOME AT NIGHT ON A DARK, WINDING ROAD, BOTH HEADLIGHTS SUDDENLY WENT OUT!!!! THERE WAS NO LIGHT! PITCH BLACK! CRAZY! I COULDN'T BELIEVE THAT MY LIGHTS WERE OUT. MY BRIGHTS WERE NOT WORKING EITHER. I DIDN'T KNOW WHAT HAPPENED TO THE CAR! I THOUGHT I WAS GOING TO WRECK/CRASH. I WAS ABOUT 18 M…

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WHILE DRIVING MY 2004 TOYOTA PRIUS HOME AT NIGHT ON A DARK, WINDING ROAD, BOTH HEADLIGHTS SUDDENLY WENT OUT!!!! THERE WAS NO LIGHT! PITCH BLACK! CRAZY! I COULDN'T BELIEVE THAT MY LIGHTS WERE OUT. MY BRIGHTS WERE NOT WORKING EITHER. I DIDN'T KNOW WHAT HAPPENED TO THE CAR! I THOUGHT I WAS GOING TO WRECK/CRASH. I WAS ABOUT 18 MILES FROM HOME. AS I DROVE, I TURNED ON MY DOME LIGHTS SO THE ONCOMING TRAFFIC COULD SEE ME. AFTER TURNING THE CAR LIGHTS ON AND OFF, THEY CAME BACK ON, BUT WHAT A NIGHTMARE!!!!! I FOUND OUT THAT OTHER TOYOTA PRIUS OWNERS HAD THE SAME PROBLEM WITH THERE CARS. TOYOTA NEEDS TO FIX THIS PROBLEM!!!!!!!!!!!!!! TOYOTA NEEDS TO RECALL AND REPLACE THESE FAULTY HEADLIGHTS! *TR

NHTSA ODI #10482399

92,521 miles · Oct 24, 2012
EngineService Brakes, Hydraulic

MY 24 YR. OLD CHILD WAS DRIVING OUT OF A DRIVEWAY AT 5 MPH WHEN THE CAR STOPPED AND ALL WARNING LIGHTS INCLUDING BRAKES AND ENGINE AND TRIANGLE WENT ON. IT WOULD NOT RESTART. IT WOULD NOT TAKE A BATTERY JUMP. HAD IT TOWED TO TOYOTA SERVICE AND THEY DISCOVERED CODE P0335 PRESENT AND VERIFIED A FAULTY CRANKSHAFT POSITION SENSOR, R…

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MY 24 YR. OLD CHILD WAS DRIVING OUT OF A DRIVEWAY AT 5 MPH WHEN THE CAR STOPPED AND ALL WARNING LIGHTS INCLUDING BRAKES AND ENGINE AND TRIANGLE WENT ON. IT WOULD NOT RESTART. IT WOULD NOT TAKE A BATTERY JUMP. HAD IT TOWED TO TOYOTA SERVICE AND THEY DISCOVERED CODE P0335 PRESENT AND VERIFIED A FAULTY CRANKSHAFT POSITION SENSOR, REPLACED IT, AND CLEANED THROTTLE BODY. THE CAR WORKS NOW. COST FOR DIAGNOSIS AND SERVICE WAS $367.07. THIS FAULTY PART WAS A PART OF A RECALL DATED IN 2006 FOR 2001 AND 2002 PRIUSES. WE WISH TO ADVISE THE AGENCY THAT WE BELIEVE THE YEAR 2004 AND PERHAPS OTHER YEARS OUGHT TO BE CONSIDERED FOR THE SAME RECALL AS THE 2001 AND 2002 PRIUS MODELS WITH RESPECT TO A FAULTY CRANKSHAFT POSITION SENSOR. WE BELIEVE OUR CAR HAD A FAULTY SENSOR AND THAT WE SHOULD BE A PART OF THE EARLIER RECALL, AND ALSO OBTAIN A FULL REIMBURSEMENT FOR CHARGES. THIS SUDDEN STOPPING BY THE VEHICLE POSES A VERY DANGEROUS SITUATION FOR ANY DRIVER. OUR CHILD WOULD HAVE BEEN ON A MAJOR HIGHWAY JUST A FEW MINUTES LATER AND COULD HAVE BEEN THE VICTIM OF A HORRENDOUS ACCIDENT. WE URGE YOUR AGENCY TO BE PROACTIVE IN INVESTIGATING THIS MATTER. THANK YOU. *TR

NHTSA ODI #10482058

249,000 miles · Oct 13, 2012
Electrical SystemExterior Lighting

2004 TOYOTA PRIUS WITH HID HEADLIGHTS IS USED AS A TAXI CAB. ON SEPTEMBER 25TH, 2012 THE DRIVERS SIDE HEADLIGHT WOULD BEGIN TO FLICKER AND TURN OFF AFTER AROUND FIVE MINUTES OF OPERATION. THE HID BULB REPLACEMENT DID NOT RESOLVE THE MATTER. HEADLIGHTS MUST BE TURNED OFF AND THEN ON AGAIN IN ORDER TO RESUME THEIR OPERATION. *TR

NHTSA ODI #10480025

141,000 miles · Oct 11, 2012
Electrical System

. 10/09/2012 I WENT TO START MY 2004 PRIUS I HIT THE POWER BUTTON AND THE DASHBOARD LIGHTS HAD NOT WORK. YOU DID NOT KNOW THE STATUS OF THE CAR. ACTUATED THE POWER SWITCH AND THE BRAKE PEDDLE NUMEROUS TIMES TO NO AVAIL. I TRIED TO SELECT THE GEAR AND THE CAR WOULD MOVE. BUT DASH BOARD DISPLAY DID NOT LIGHT. THE LIGHTS AND TURN …

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. 10/09/2012 I WENT TO START MY 2004 PRIUS I HIT THE POWER BUTTON AND THE DASHBOARD LIGHTS HAD NOT WORK. YOU DID NOT KNOW THE STATUS OF THE CAR. ACTUATED THE POWER SWITCH AND THE BRAKE PEDDLE NUMEROUS TIMES TO NO AVAIL. I TRIED TO SELECT THE GEAR AND THE CAR WOULD MOVE. BUT DASH BOARD DISPLAY DID NOT LIGHT. THE LIGHTS AND TURN SIGNALS WORK FINE. I DROVE 15 MILES HOME WITH ON DISPLAY. I SELECTED THE PARK BUTTON AND THE CAR PARKED I WENT TO TURN OFF THE POWER BUTTON AND THE CAR WOULD NOT TURN OFF THE WAS IN THE BATTERY MODE. I TRIED TO SHUT IT OFF BY DISCONNECTING THE 12 VOLT BATTERY TO NO AVAIL. I FOUND A FUSE THAT IF I PULLED IT OUT THE CAR WOULD SHUT OFF. I TRIED THE POWER NUMEROUS TIMES AND THE CAR TURN ON AND WITH THE DASHBOARD DISPLAY WORKING. ON THE MORNING OF 10/10/2012 I TRIED GO TO WORK AND WHEN THE POWER AND THE BRAKE ARE PUSHED THE DASH BOARD LIGHTS WOULD NOT LIGHT. THE CAR WOULD MOVE IF SELECTED TO DRIVE NOW THE ENGINE WAS RUNNING BECAUSE THE CAR WAS COLD. I PLACED THE CAR IN PARK AND SELECTED THE POWER BUTTON TO OFF NOW THE ENGINE WILL SHUT OFF. AGAIN I TRIED THE POWER AND THE BRAKE NUMEROUS TIMES TO NO AVAIL. I TRIED THE FUSE TRICK AGAIN IT WORKED THE ENGINE STOPPED. REPLACED THE FUSE AND TRIED THE POWER BUTTON IT WORK AND THE DASH DISPLAY WERE LIGHTED WITH NUMEROUS LIGHTS BECAUSE I SHUT THE DOWN IN UNAPPROVED MODE. TURNED THE POWER SWITCH ON & OFF. NUMEROUS TIMES ALL LIGHT WERE NORMAL EXCEPT THE CHECK ENGINE WAS ON I DROVE TO THE TOYOTA DEALER. I WAS TOLD THAT IS A NORMAL ISSUE THE DASHBOARD DISPLAYS GO BAD. I UNDERSTAND THE DASHBOARD DISPLAY CAN GO BAD. MY ISSUE IS THE SAFETY PROBLEM THAT WHEN THE DISPLAY FAILS THE POWER BUTTON DOES NOT SHUT CAR OFF IN THE BATTERY MODE OR THE ENGINE MODE. THAT'S A BIG ISSUE . *TR

NHTSA ODI #10479809

69,135 miles · Sep 11, 2012
Power Train

THE DASH GEAR SELECTOR (COMMON TO 2004 - 2009 G2 PRIUS) BEGAN CLICKING WHEN I CHANGED GEARS (R-D-N) I RESEARCHED THE SUBJECT AND LEARNED THAT THIS CAN LEAD TO THE SHIFTER LOCKING IN D OR R, A HAZARDOUS CONDITION. I ALSO LEARNED THAT SOME DIY OWNERS HAVE DISCOVERED A WARPED DUST PLATE IN THE SHIFTER COMPONENT. IT CAUSES THIS P…

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THE DASH GEAR SELECTOR (COMMON TO 2004 - 2009 G2 PRIUS) BEGAN CLICKING WHEN I CHANGED GEARS (R-D-N) I RESEARCHED THE SUBJECT AND LEARNED THAT THIS CAN LEAD TO THE SHIFTER LOCKING IN D OR R, A HAZARDOUS CONDITION. I ALSO LEARNED THAT SOME DIY OWNERS HAVE DISCOVERED A WARPED DUST PLATE IN THE SHIFTER COMPONENT. IT CAUSES THIS PROBLEM. THEIR SOLUTION IS TO REMOVE THE PLATE, TRIM IT, AND REASSEMBLE THE PART. LINK 1 BELOW IS A GOOGLE SEARCH THAT REVEALS THE OTHER TWO LINKS I INCLUDED. NOT ALL OF THE HITS ARE RELEVANT. THE THIRD LINK HAS A VIDEO WITH CLEAR IMAGES OF THE PROBLEM AND THE DIY 'SOLUTION.' HTTPS://WWW.GOOGLE.COM/SEARCH?NUM=100&HL=EN&SAFE=OFF&COMPLETE=0&SITE=WEBHP&Q=PRIUS+%22GEAR+SHIFT%22+CLICK+STICKING&OQ=PRIUS+%22GEAR+SHIFT%22+CLICK+STICKING&GS_L=SERP.3...2446378.2449925.0.2450814.0.0.0.0.0.0.0.0..0.0.LES%3BCPSUGRPQ1..0.0...1.1.IIMLXLK1U2C HTTP://PRIUSCHAT.COM/THREADS/GEAR-SHIFTER-STICKS.38199/PAGE-2 HTTP://PRIUSCHAT.COM/THREADS/HOW-TO-REPLACE-2G-GEARSHIFT-LEVER.65102/ I AM BELIEVE THAT TOYOTA SHOULD BE ASKED TO RECALL THESE CARS TO REPLACE THIS DUST PLATE (OR THE SHIFTER MODULE.) UNFORTUNATELY THE GEAR SHIFT MODULE INCLUDED WITH THE CAR DOES NOT HAVE A LIFETIME CONSISTENT WITH THE 10 YEAR/100,000 MILE WARRANTY ON THE TRACTION BATTERY. IT IS DANGEROUS TO HAVE OWNERS MAKE THIS REPAIR THEMSELVES. THIS COULD BE AVOIDED IF TOYOTA WERE REQUIRED TO DO IT INSTEAD. *TR

NHTSA ODI #10475045

59,600 miles · Jul 25, 2012
Electrical System

UPON STARTING THE CAR ONE MORNING I NOTICED THE SPEEDOMETER, FUEL AND GEAR INDICATOR DIGITAL READOUTS WERE NOT WORKING. I RESEARCHED THE PROBLEM ON THE INTERNET AND NARROWED THE PROBLEM TO A FAULTY COMBINATION METER (BAD SOLDER). THIS PROBLEM HAS BEEN OCCURRING WITH NUMEROUS OTHER PRIUS OWNERS ACCORDING TO FORUMS AND SUCH. I PUR…

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UPON STARTING THE CAR ONE MORNING I NOTICED THE SPEEDOMETER, FUEL AND GEAR INDICATOR DIGITAL READOUTS WERE NOT WORKING. I RESEARCHED THE PROBLEM ON THE INTERNET AND NARROWED THE PROBLEM TO A FAULTY COMBINATION METER (BAD SOLDER). THIS PROBLEM HAS BEEN OCCURRING WITH NUMEROUS OTHER PRIUS OWNERS ACCORDING TO FORUMS AND SUCH. I PURCHASED THE CAR AT A FORD DEALERSHIP AND ALSO PURCHASED THEIR FORD ESP BASE CARE PLAN. CLEARLY THE PLAN STATED THE SPEEDOMETER/ODOMETER, ELECTRICAL OR MECHANICAL PROBLEMS WERE COVERED. HOWEVER THE AGENT AT THE EXTENDED WARRANTY OFFICE DENIED THE CLAIM. SO MY CAR SITS AT A TOYOTA DEALERSHIP WITH THE DASH APART AND THE APPRAISED VALUE OF THE CAR LESS $2000.00 ACCORDING TO THE SALES DEPT. BECAUSE THE MILEAGE IS UNKNOWN. TOYOTA HAS YET TO DECLARE A RECALL FOR THE PROBLEM WHICH COULD RESULT IN DEATH IN SOME CASES IF NOT PROPERLY ADDRESSED. I HAVE TWO CHILDREN AND VALUE THEIR LIVES. I HOPE AND PRAY THAT TOYOTA COMES AROUND. *TR

NHTSA ODI #10467653

160,000 miles · Jul 16, 2012
Electrical SystemExterior Lighting

THE HEADLIGHTS GO OUT RANDOMLY WHILE DRIVING AT NIGHT. YOU HAVE TO TURN THEM OFF AND THEN TURN THEM BACK ON FOR THEM TO WORK AND THEY ONLY LAST A MINUTE AFTER THAT. HUGE SAFETY ISSUE!! *TR

NHTSA ODI #10465922

92,000 miles · Jun 22, 2012
Electrical System

I NEED YOUR HELP! THERE IS A MANUFACTURING DEFECT WELL DOCUMENTED AS A COMMON PROBLEM WITH 2004 TOYOTA PRIUS MULTI-FUNCTIONAL DISPLAY (MFD). THE PROBLEM IS THAT THE 60 PIN CONNECTOR ON THE PRINTED CIRCUIT BOARD OF THE MFD SOMETIMES DEVELOPS A PLAY IN THE CONNECTION AND HENCE THE SPORADIC DISPLAY. I WROTE TO TOYOTA CUSTOMER S…

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I NEED YOUR HELP! THERE IS A MANUFACTURING DEFECT WELL DOCUMENTED AS A COMMON PROBLEM WITH 2004 TOYOTA PRIUS MULTI-FUNCTIONAL DISPLAY (MFD). THE PROBLEM IS THAT THE 60 PIN CONNECTOR ON THE PRINTED CIRCUIT BOARD OF THE MFD SOMETIMES DEVELOPS A PLAY IN THE CONNECTION AND HENCE THE SPORADIC DISPLAY. I WROTE TO TOYOTA CUSTOMER SERVICE. TOYOTA INSTRUCTED ME TO TAKE MY CAR TO THE DEALER AND SPEAK TO TOYOTA. TOLD ME THAT HE DID TALK TO THE TOYOTA REP AND EXPLAINED TO HIM THAT I HAD BEEN TAKING VERY GOOD CARE OF MY CAR AND THAT THIS MFD PROBLEM WAS NOT MY DOING. TOLD ME THAT IT WOULD COST $980.57 TO INSTALL A REMANUFACTURED MFD. AND THAT THE TOYOTA REP IS ONLY GOING TO CONTRIBUTE $250. SO NET OUT OF POCKET FOR ME WOULD BE A SUBSTANTIAL AMOUNT OF $730.57. IT IS UNFAIR FOR TOYOTA CUSTOMER SERVICE TO ASK ME TO PAY, SINCE THIS IS A COMMON PROBLEM WITH 2004 TOYOTA PRIUS MFDS THAT IS WELL DOCUMENTED TO BE A COMMON PROBLEM. I HAVE ALREADY SPENT A LOT OF TIME AND MONEY ON THE PROBLEM. TOYOTA CUSTOMER SERVICE IS TAKING THE APPROACH THAT IT IS OUT OF WARRANTY AND THERE IS NO RECALL SO WE DON'T WANT TO DO ANYTHING. THAT LOGIC IS WRONG. IF THERE IS A COMMON PROBLEM THAT MAY HAVE NOT ESCALATED TO A RECALL STATUS, THAT DOES NOT MEAN THAT THERE IS NO PROBLEM. RECALL IS IF ENOUGH PEOPLE HAVE PROBLEMS. MEANWHILE, YOU CANNOT DENY FOR ALL THE PEOPLE WHO ARE STUCK WITH THIS PROBLEM. IT HAS BEEN CLEARLY DEMONSTRATED THAT THIS IS A MANUFACTURING DEFECT THAT TOYOTA IS RESPONSIBLE. YOUR HIGH LEVEL INTERVENTION IS NEEDED. PLEASE WRITE TO TOYOTA DEMANDING THAT IT WOULD ONLY BE FAIR SINCE THE MFD PROBLEM IS CLEARLY DOCUMENTED TO BE A MANUFACTURING DEFECT, THAT TOYOTA REPAIR WITHOUT DELAY AT NO COST TO THE CLIENT, SINCE HE HAS ALREADY SUFFERED ENOUGH. THANKS! INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6) *TT

NHTSA ODI #10462717

171,740 miles · Jun 22, 2012
Electrical SystemExterior Lighting

RANDOM FAILURE OF LIGHTS, BEGAN WITH DRIVER?S SIDE AND CONTINUES TO OCCUR RANDOMLY WITH GREATER FREQUENCY. PASSENGER SIDE ALSO TURNS OFF RANDOMLY, THOUGH WITH LESS FREQUENCY. MANY OCCASIONS, I HAVE HAD BOTH LIGHTS TURN OFF WHILE DRIVING. *TT

NHTSA ODI #10462715

215,000 miles · Jun 12, 2012
Exterior Lighting

HAD THE HID HEADLIGHTS REPLACED 6 MONTHS AGO BECAUSE THEY WERE INTERMITTENTLY GOING ON AND OFF. SAME THING IS HAPPENING AGAIN. *TR

NHTSA ODI #10461371

Official recalls

6

12V536000 · Engine And Engine Cooling; Hybrid Propulsion System: Inverter

Nov 14, 2012

Toyota is recalling certain model year 2004-2009 Prius vehicles manufactured August 6, 2003, through March 30, 2009 and FCHV-adv vehicles manufactured December 12, 2008, through September 13, 2011. During manufacturing, a scratch may have occurred inside of the electrically driven water pump at the coil wire. The coil wire may corrode at the scratched portion.

Consequence & remedy

Consequence: The corroded coil wire may break and the water pump could stop. The corroded coil wire could cause a short circuit between coil wires and a possible open fuse, creating a stall-like condition of the hybrid system while the vehicle is being driven. This may increase the risk of a vehicle crash.

Remedy: Toyota will notify its owners, and dealers will replace the electric water pump, free of charge. The recall began on January 17, 2013. Owners may contact their Toyota dealer or the Toyota Customer Experience Center at 1-800-331-4331.

Additional source detail variants (2)

Hybrid Propulsion System: Inverter

Toyota is recalling certain model year 2004-2009 Prius vehicles manufactured August 6, 2003, through March 30, 2009 and FCHV-adv vehicles manufactured December 12, 2008, through September 13, 2011. During manufacturing, a scratch may have occurred inside of the electrically driven water pump at the coil wire. The coil wire may corrode at the scratched portion.

Consequence: The corroded coil wire may break and the water pump could stop. The corroded coil wire could cause a short circuit between coil wires and a possible open fuse, creating a stall-like condition of the hybrid system while the vehicle is being driven. This may increase the risk of a vehicle crash.

Remedy: Toyota will notify its owners, and dealers will replace the electric water pump, free of charge. The recall began on January 17, 2013. Owners may contact their Toyota dealer or the Toyota Customer Experience Center at 1-800-331-4331.

Engine And Engine Cooling

Toyota is recalling certain model year 2004-2009 Prius vehicles manufactured August 6, 2003, through March 30, 2009 and FCHV-adv vehicles manufactured December 12, 2008, through September 13, 2011. During manufacturing, a scratch may have occurred inside of the electrically driven water pump at the coil wire. The coil wire may corrode at the scratched portion.

Consequence: The corroded coil wire may break and the water pump could stop. The corroded coil wire could cause a short circuit between coil wires and a possible open fuse, creating a stall-like condition of the hybrid system while the vehicle is being driven. This may increase the risk of a vehicle crash.

Remedy: Toyota will notify its owners, and dealers will replace the electric water pump, free of charge. The recall began on January 17, 2013. Owners may contact their Toyota dealer or the Toyota Customer Experience Center at 1-800-331-4331.

12V537000 · Steering; Steering:gear Box:shaft Sector

Nov 14, 2012

Toyota is recalling certain model year 2004-2009 Prius vehicles manufactured August 5, 2003, through March 30, 2009. The affected vehicles have a steering intermediate extension shaft assembly built with metal splines that complete the connection from the steering wheel to the steering gear. These splines may have been manufactured with an insufficient hardness.

Consequence & remedy

Consequence: Over time, the splines may wear and eventually fail resulting in a loss of steering ability, increasing the risk of a vehicle crash.

Remedy: Toyota will notify owners, and dealers will inspect the extension shaft and replace it if it is one with insufficient hardness, free of charge. The recall began during December 2012. Owners may contact their Toyota dealer or the Toyota Customer Experience Center at 1-800-331-4331.

Additional source detail variants (2)

Steering:gear Box:shaft Sector

Toyota is recalling certain model year 2004-2009 Prius vehicles manufactured August 5, 2003, through March 30, 2009. The affected vehicles have a steering intermediate extension shaft assembly built with metal splines that complete the connection from the steering wheel to the steering gear. These splines may have been manufactured with an insufficient hardness.

Consequence: Over time, the splines may wear and eventually fail resulting in a loss of steering ability, increasing the risk of a vehicle crash.

Remedy: Toyota will notify owners, and dealers will inspect the extension shaft and replace it if it is one with insufficient hardness, free of charge. The recall began during December 2012. Owners may contact their Toyota dealer or the Toyota Customer Experience Center at 1-800-331-4331.

Steering

Toyota is recalling certain model year 2004-2009 Prius vehicles manufactured August 5, 2003, through March 30, 2009. The affected vehicles have a steering intermediate extension shaft assembly built with metal splines that complete the connection from the steering wheel to the steering gear. These splines may have been manufactured with an insufficient hardness.

Consequence: Over time, the splines may wear and eventually fail resulting in a loss of steering ability, increasing the risk of a vehicle crash.

Remedy: Toyota will notify owners, and dealers will inspect the extension shaft and replace it if it is one with insufficient hardness, free of charge. The recall began during December 2012. Owners may contact their Toyota dealer or the Toyota Customer Experience Center at 1-800-331-4331.

09V388000 · Vehicle Speed Control:accelerator Pedal

Oct 5, 2009

TOYOTA IS RECALLING CERTAIN MODEL YEAR 2004-2010 PASSENGER VEHICLES. THE ACCELERATOR PEDAL CAN GET STUCK IN THE WIDE OPEN POSITION DUE TO ITS BEING TRAPPED BY AN UNSECURED OR INCOMPATIBLE DRIVER'S FLOOR MAT.

Consequence & remedy

Consequence: A STUCK OPEN ACCELERATOR PEDAL MAY RESULT IN VERY HIGH VEHICLE SPEEDS AND MAKE IT DIFFICULT TO STOP THE VEHICLE, WHICH COULD CAUSE A CRASH, SERIOUS INJURY OR DEATH.

Remedy: TOYOTA FILED AN AMENDED DEFECT REPORT ON NOVEMBER 25, 2009, STATING THAT DEALERS WILL MODIFY THE ACCELERATOR PEDAL AND, ON CERTAIN VEHICLES, ALTER THE SHAPE OF THE FLOOR SURFACE UNDER THE PEDAL. THESE CHANGES ADDRESS THE RISK OF PEDAL ENTRAPMENT DUE TO INTERFERENCE WITH THE FLOOR MAT. REDESIGNED ACCELERATOR PEDALS WILL BECOME AVAILABLE BEGINNING IN APRIL 2010 AND DEALERS WILL REPLACE ANY MODIFIED PEDAL WITH THE NEW PEDAL IF DESIRED. ALSO, DEALERS WILL REPLACE ANY GENUINE TOYOTA OR LEXUS ALL-WEATHER FLOOR MATS WITH REDESIGNED ALL-WEATHER MATS, OR REPURCHASE THE PREVIOUS MATS FROM OWNERS WHO DO NOT WANT THE NEW ONES. ADDITIONALLY, SOFTWARE MODIFICATIONS WILL BE INSTALLED ON CAMRY, AVALON AND LEXUS ES 350, IS 350 AND IS 250 MODELS THAT WILL ENSURE THAT THE BRAKE OVERRIDES THE ACCELERATOR IN THE EVENT BOTH BRAKE AND ACCELERATOR PEDALS ARE APPLIED. TOYOTA WILL BEGIN MAILING LETTERS TO OWNERS ON DECEMBER 31, 2009. OWNERS MAY CONTACT TOYOTA AT 1-800-331-4331, LEXUS AT 1-800-255-3987.

06V188000 · Steering:electric Power Assist System

May 31, 2006

THE INTERMEDIATE SHAFT AND SLIDING YOKE IN THE ELECTRIC POWER STEERING SYSTEM CAN CRACK WHEN LARGE FORCES ARE APPLIED AND THE CONNECTION MAY SEPARATE OR THE SLEEVE MAY FRACTURE.

Consequence & remedy

Consequence: THIS COULD RESULT IN A LOSS OF STEERING CONTROL OF THE VEHICLE.

Remedy: TOYOTA WILL REPLACE THE STEERING INTERMEDIATE SHAFT AND INSPECT THE SLIDING YOKE AND REPLACE IT IF NECESSARY. THE RECALL BEGAN ON JUNE 9, 2006. OWNERS MAY CONTACT TOYOTA AT 1-800-331-4331.

06V096000 · Air Bags

Apr 3, 2006

ON CERTAIN VEHICLES, DUE TO IMPROPER ASSEMBLY OF THE AIR BAG INFLATOR, WHICH IS USED IN THE SIDE AIR BAG, THE CURTAIN SHIELD AIR BAG, AND THE KNEE AIR BAG ASSEMBLY, SOME INFLATORS WERE PRODUCED WITH AN INSUFFICIENT AMOUNT OF THE HEATING AGENTS NECESSARY FOR PROPER AIR BAG DEPLOYMENT. IN THIS CONDITION, THE EXPANSION FORCE OF THE GAS MAY BE INSUFFICIENT TO PROPERLY INFLATE THE AIR BAG WHEN THE SRS SYSTEM IS ACTIVATED DURING A CRASH.

Consequence & remedy

Consequence: THIS MAY INCREASE THE RISK OF INJURY TO THE OCCUPANT IN THE INVOLVED SEATING POSITION IN THE EVENT OF A CRASH.

Remedy: DEALERS WILL REPLACE THE SPECIFIC SRS AIR BAG. THE RECALL BEGAN ON APRIL 6, 2006. OWNERS MAY CONTACT TOYOTA AT 1-888-270-9371, SCION AT 1-866-548-1851, OR LEXUS AT 1-800-255-3987.

04V558000 · Exterior Lighting:brake Lights:switch

Nov 22, 2004

CERTAIN PASSENGER VEHICLES MAY BE EQUIPPED WITH AN IMPROPERLY DESIGNED BRAKE LIGHT SWITCH. A SILICON OXIDE BUILD-UP OCCURS ON THE CONTACTS INSIDE THE BRAKE LIGHT SWITCH, WHICH CAN MAKE IT INOPERABLE.

Consequence & remedy

Consequence: IF THE SWITCH IS INOPERABLE, THE BRAKE LIGHTS WILL NOT ILLUMINATE AND CAN INCREASE THE RISK OF A CRASH.

Remedy: DEALERS WILL REPLACE THE BRAKE LIGHT SWITCH. THE RECALL BEGAN DURING DECEMBER 2004. OWNERS SHOULD CONTACT TOYOTA AT 1-800-331-4331.

Model-level recall history does not show whether a particular VIN is affected or has received a repair. Check a VIN with NHTSA ↗

NHTSA investigations

3

DP22005 · Pedestrian Alert Sounds

Opened Jan 27, 2023 · Closed Aug 7, 2023

Status: closed (inferred from source dates) · Electrical System:propulsion System

NHTSA received a petition on or about July 18, 2022, requesting that Federal Motor Vehicle Safety Standard (FMVSS) 141 be applied to all electric and hybrid vehicles operating in the United States. The petition can be reviewed at NHTSA.gov under ODI Number 11486072. FMVSS 141 establishes performance requirements for pedestrian alert sounds for motor vehicles. The standard applies to hybrid and electric vehicles that have a gross vehicle weight rating of 4,536 KG or less or are defined as low-speed vehicles. The standard became fully applicable to all such vehicles manufactured on or after March 1, 2021.On January 27, 2023, NHTSA opened Defect Petition (DP) 22-005 to evaluate the subject matter described in the petition. On June 24, 2023 and as supplemented on June 25, 2023, the petitioner notified NHTSA he was withdrawing his petition. The petitioner indicated that, based on his review of data, there is no justification for asserting potential benefits that could be derived from actions sought by my petition. Based on the petitioner's withdrawal, DP22-005 is closed. Closure of this DP does not represent a determination by NHTSA regarding the subject matter of the petition.

DP13001 · Intermediate Steering Shaft Separation

Opened Feb 21, 2013 · Closed Apr 8, 2020

Status: closed (inferred from source dates) · Steering; Steering:column; Steering:linkages

The Office of Defects Investigation (ODI) received a January 2013 defect petition requesting that it open an investigation on Model Year (MY) 2004-2009 Toyota Prius vehicles to address a possible manufacturing safety defect related to the steering column intermediate shaft.During the defect petition evaluation, ODI: 1.Reviewed the petition and its enclosures; 2.Reviewed the subject steering system layout; 3.Examined the Petition Vehicle?s history, including its repair history; 4.Reviewed and followed-up potentially related consumer complaints; 5.Assessed Safety Recalls 06V-188 and 12V-537; and, 6.Requested and examined complaint, claim, field report, service history, and warranty information from Toyota.ODI's review revealed that the petition vehicle had been recalled (Recall 06V188) to remedy a defect in the system identified in the petition with the remedy taking place prior to the failure that prompted the petition. Circumstances point to incorrect reassembly of the petitioner's vehicle by those who performed the recall remedy.ODI examined the issues raised by this petition to identify any related safety defect trend in the general subject vehicle population.That review identified a low rate of related consumer complaints (twenty-five over a eight year period from a population of over 600,000 vehicles) and no pattern that would identify either a safety defect not already covered by the two existing steering safety recalls by Toyota or a systematic problem with either recall remedy.Based on this evaluation, ODI does not believe that additional investigation will lead to a finding that a defect related to motor vehicle safety exists in the subject vehicles. Therefore, in view of the need to allocate and prioritize NHTSA?s limited resources to best accomplish the agency's safety mission, the petition is denied. The denial of this petition does not constitute a finding by NHTSA that a safety-related defect does not exist. The agency reserves the right to take further action if warranted by the circumstances.For more information, see the Federal Register notice in the public file for this action (https://www.nhtsa.gov/recalls#vehicle, select NHTSA ID, enter: DP13001)The ODI reports cited above can be reviewed on-line (https://www.nhtsa.gov/recalls#vehicle) under the following NHTSA ID numbers:10407520, 10418710, 10429551, 10473654, 10478195, 10478053, 10437229, 10489425, 10510722, 10639984, 10648277, 10499778, 10712626, 10723196, 10787530, 10808124, 10838803, 11071646, 11098144, 11099507, 11102659, 11160767, 11192607, 11287550, 11287606

Additional source detail variants (3)

Steering:column

The Office of Defects Investigation (ODI) received a January 2013 defect petition requesting that it open an investigation on Model Year (MY) 2004-2009 Toyota Prius vehicles to address a possible manufacturing safety defect related to the steering column intermediate shaft.During the defect petition evaluation, ODI: 1.Reviewed the petition and its enclosures; 2.Reviewed the subject steering system layout; 3.Examined the Petition Vehicle?s history, including its repair history; 4.Reviewed and followed-up potentially related consumer complaints; 5.Assessed Safety Recalls 06V-188 and 12V-537; and, 6.Requested and examined complaint, claim, field report, service history, and warranty information from Toyota.ODI's review revealed that the petition vehicle had been recalled (Recall 06V188) to remedy a defect in the system identified in the petition with the remedy taking place prior to the failure that prompted the petition. Circumstances point to incorrect reassembly of the petitioner's vehicle by those who performed the recall remedy.ODI examined the issues raised by this petition to identify any related safety defect trend in the general subject vehicle population.That review identified a low rate of related consumer complaints (twenty-five over a eight year period from a population of over 600,000 vehicles) and no pattern that would identify either a safety defect not already covered by the two existing steering safety recalls by Toyota or a systematic problem with either recall remedy.Based on this evaluation, ODI does not believe that additional investigation will lead to a finding that a defect related to motor vehicle safety exists in the subject vehicles. Therefore, in view of the need to allocate and prioritize NHTSA?s limited resources to best accomplish the agency's safety mission, the petition is denied. The denial of this petition does not constitute a finding by NHTSA that a safety-related defect does not exist. The agency reserves the right to take further action if warranted by the circumstances.For more information, see the Federal Register notice in the public file for this action (https://www.nhtsa.gov/recalls#vehicle, select NHTSA ID, enter: DP13001)The ODI reports cited above can be reviewed on-line (https://www.nhtsa.gov/recalls#vehicle) under the following NHTSA ID numbers:10407520, 10418710, 10429551, 10473654, 10478195, 10478053, 10437229, 10489425, 10510722, 10639984, 10648277, 10499778, 10712626, 10723196, 10787530, 10808124, 10838803, 11071646, 11098144, 11099507, 11102659, 11160767, 11192607, 11287550, 11287606

Steering:linkages

The Office of Defects Investigation (ODI) received a January 2013 defect petition requesting that it open an investigation on Model Year (MY) 2004-2009 Toyota Prius vehicles to address a possible manufacturing safety defect related to the steering column intermediate shaft.During the defect petition evaluation, ODI: 1.Reviewed the petition and its enclosures; 2.Reviewed the subject steering system layout; 3.Examined the Petition Vehicle?s history, including its repair history; 4.Reviewed and followed-up potentially related consumer complaints; 5.Assessed Safety Recalls 06V-188 and 12V-537; and, 6.Requested and examined complaint, claim, field report, service history, and warranty information from Toyota.ODI's review revealed that the petition vehicle had been recalled (Recall 06V188) to remedy a defect in the system identified in the petition with the remedy taking place prior to the failure that prompted the petition. Circumstances point to incorrect reassembly of the petitioner's vehicle by those who performed the recall remedy.ODI examined the issues raised by this petition to identify any related safety defect trend in the general subject vehicle population.That review identified a low rate of related consumer complaints (twenty-five over a eight year period from a population of over 600,000 vehicles) and no pattern that would identify either a safety defect not already covered by the two existing steering safety recalls by Toyota or a systematic problem with either recall remedy.Based on this evaluation, ODI does not believe that additional investigation will lead to a finding that a defect related to motor vehicle safety exists in the subject vehicles. Therefore, in view of the need to allocate and prioritize NHTSA?s limited resources to best accomplish the agency's safety mission, the petition is denied. The denial of this petition does not constitute a finding by NHTSA that a safety-related defect does not exist. The agency reserves the right to take further action if warranted by the circumstances.For more information, see the Federal Register notice in the public file for this action (https://www.nhtsa.gov/recalls#vehicle, select NHTSA ID, enter: DP13001)The ODI reports cited above can be reviewed on-line (https://www.nhtsa.gov/recalls#vehicle) under the following NHTSA ID numbers:10407520, 10418710, 10429551, 10473654, 10478195, 10478053, 10437229, 10489425, 10510722, 10639984, 10648277, 10499778, 10712626, 10723196, 10787530, 10808124, 10838803, 11071646, 11098144, 11099507, 11102659, 11160767, 11192607, 11287550, 11287606

Steering

The Office of Defects Investigation (ODI) received a January 2013 defect petition requesting that it open an investigation on Model Year (MY) 2004-2009 Toyota Prius vehicles to address a possible manufacturing safety defect related to the steering column intermediate shaft.During the defect petition evaluation, ODI: 1.Reviewed the petition and its enclosures; 2.Reviewed the subject steering system layout; 3.Examined the Petition Vehicle?s history, including its repair history; 4.Reviewed and followed-up potentially related consumer complaints; 5.Assessed Safety Recalls 06V-188 and 12V-537; and, 6.Requested and examined complaint, claim, field report, service history, and warranty information from Toyota.ODI's review revealed that the petition vehicle had been recalled (Recall 06V188) to remedy a defect in the system identified in the petition with the remedy taking place prior to the failure that prompted the petition. Circumstances point to incorrect reassembly of the petitioner's vehicle by those who performed the recall remedy.ODI examined the issues raised by this petition to identify any related safety defect trend in the general subject vehicle population.That review identified a low rate of related consumer complaints (twenty-five over a eight year period from a population of over 600,000 vehicles) and no pattern that would identify either a safety defect not already covered by the two existing steering safety recalls by Toyota or a systematic problem with either recall remedy.Based on this evaluation, ODI does not believe that additional investigation will lead to a finding that a defect related to motor vehicle safety exists in the subject vehicles. Therefore, in view of the need to allocate and prioritize NHTSA?s limited resources to best accomplish the agency's safety mission, the petition is denied. The denial of this petition does not constitute a finding by NHTSA that a safety-related defect does not exist. The agency reserves the right to take further action if warranted by the circumstances.For more information, see the Federal Register notice in the public file for this action (https://www.nhtsa.gov/recalls#vehicle, select NHTSA ID, enter: DP13001)The ODI reports cited above can be reviewed on-line (https://www.nhtsa.gov/recalls#vehicle) under the following NHTSA ID numbers:10407520, 10418710, 10429551, 10473654, 10478195, 10478053, 10437229, 10489425, 10510722, 10639984, 10648277, 10499778, 10712626, 10723196, 10787530, 10808124, 10838803, 11071646, 11098144, 11099507, 11102659, 11160767, 11192607, 11287550, 11287606

PE05029 · Engine Stalling

Opened May 31, 2005 · Closed Oct 12, 2005

Status: closed (inferred from source dates) · Engine And Engine Cooling; Engine And Engine Cooling:engine; Unknown Or Other

ODI OPENED PE05-029 BASED ON 33 REPORTS OF ALLEGED GASOLINE ENGINE STALLING ON THE SUBJECT VEHICLES.THE SUBJECT VEHICLES ARE GASOLINE/ ELECTRIC HYBRID VEHICLES THAT CAN BE OPERATED IN GASOLINE OR ELECTRIC MODES, OR A COMBINATION OF BOTH DEPENDING ON THE POWER DEMAND.ALL REPORTS ALLEGE THAT THE GASOLINE ENGINE SHUT DOWN SUDDENLY WITHOUT WARNING.SOME OF THE COMPLAINANTS REPORTED THAT THE VEHICLE CONTINUED TO OPERATE USING THE ELECTRIC MODE FOR A PERIOD OF TIME AFTER THE GAS ENGINE STALLED AND SOME REPORTED THAT THE VEHICLE SHUT DOWN AT THE SAME TIME THAT THEY FELT THE GAS ENGINE STALLED.SOME CONSUMERS REPORTED THAT THEY WERE ABLE TO RESTART THE VEHICLE EITHER IMMEDIATELY OR AFTER ALLOWING THE VEHICLE SIT FOR A SHORT TIME, WHEREAS OTHERS REPORTED THAT THEY HAD THEIR VEHICLE TOWED.DURING PE05-029, ADDITIONAL FAILURE DATA WAS IDENTIFIED AS NOTED IN THE FAILURE REPORT SUMMARY ABOVE.THE COMPLAINT DATA REPRESENTS INCIDENTS WHERE ENGINE STALLING WAS ALLEGED OR WHERE THE VEHICLE WAS ALLEGED TO HAVE ONE OF THE VARIOUS CONDITIONS THAT CAUSES THE GAS ENGINE TO STALL.IN ITS AUGUST 26, 2005 RESPONSE TO ODI'S INFORMATION REQUEST, TOYOTA IDENTIFIED VARIOUS CONDITIONS THAT COULD CAUSE THE SUBJECT VEHICLES TO EXPERIENCE A GAS ENGINE STALL.IF THIS HAPPENS, THE DRIVER IS ALERTED BY AN AUDIBLE SOUND AND VARIOUS WARNING LIGHTS.THE VEHICLE WILL CONTINUE TO OPERATE IN THE ELECTRIC MODE AND THE ELECTRICALLY-POWERED BRAKE AND STEERING OPERATION WILL CONTINUE TO FUNCTION NORMALLY. ANALYSIS OF THE WARRANTY DATA INDICATED THAT OVER 97% OF VEHICLES EXPERIENCING A GAS ENGINE STALL RESULTED FROM AN ISSUE WITH THE PROGRAM LOGIC IN THE ELECTRONIC CONTROL MODULE (ECM) SYSTEM, WHICH MAY CAUSE THE ECM SYSTEM TO NOT START THE GAS ENGINE WHEN REQUIRED.AS A RESULT, THE VEHICLE WILL ENTER THE LIMITED OPERATION MODE DESCRIBED ABOVE.THE MAJORITY OF THE ODI COMPLAINTS ALSO INDICATED THAT THE DRIVER EXPERIENCED THIS CONDITION IN CONJUNCTION WITH THE ENGINE STALL. DURING OCTOBER 2005, TOYOTA INFORMED ODI THAT IT WOULD INITIATE A SPECIAL SERVICE CAMPAIGN (SSC) TO REPROGRAM THE ECM SOFTWARE ON APPROXIMATELY 75,000 MY 2004 AND EARLY 2005 SUBJECT VEHICLES TO ADDRESS THE GAS ENGINE STALLING CONDITION.DURING THIS SSC, DEALERS WILL ALSO APPLY SPECIAL DIELECTRIC GREASE TO A TRANSAXLE CONNECTOR TO PREVENT WATER INTRUSION WHICH MAY ALSO CAUSE SIMILAR LIMITED OPERATION CONDITIONS.BASED ON ODI'S ANALYSIS, THIS REMEDY SHOULD ADDRESS MOST OF THE INCIDENTS RESULTING IN A LIMITED OPERATION MODE.GIVEN THESE CIRCUMSTANCES, FURTHER USE OF THE AGENCY RESOURCES IN THIS MATTER DOES NOT APPEAR TO BE WARRANTED.ACCORDINGLY, THIS INVESTIGATION IS CLOSED.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT A SAFETY-RELATED DEFECT DOES NOT EXIST.THE AGENCY WILL CONTINUE TO MONITOR COMPLAINTS AND OTHER INFORMATION RELATING TO THE ALLEGED DEFECT IN THE SUBJECT VEHICLES AND TAKE FURTHER ACTION IN THE FUTURE IF WARRANTED.

Additional source detail variants (3)

Engine And Engine Cooling:engine

ODI OPENED PE05-029 BASED ON 33 REPORTS OF ALLEGED GASOLINE ENGINE STALLING ON THE SUBJECT VEHICLES.THE SUBJECT VEHICLES ARE GASOLINE/ ELECTRIC HYBRID VEHICLES THAT CAN BE OPERATED IN GASOLINE OR ELECTRIC MODES, OR A COMBINATION OF BOTH DEPENDING ON THE POWER DEMAND.ALL REPORTS ALLEGE THAT THE GASOLINE ENGINE SHUT DOWN SUDDENLY WITHOUT WARNING.SOME OF THE COMPLAINANTS REPORTED THAT THE VEHICLE CONTINUED TO OPERATE USING THE ELECTRIC MODE FOR A PERIOD OF TIME AFTER THE GAS ENGINE STALLED AND SOME REPORTED THAT THE VEHICLE SHUT DOWN AT THE SAME TIME THAT THEY FELT THE GAS ENGINE STALLED.SOME CONSUMERS REPORTED THAT THEY WERE ABLE TO RESTART THE VEHICLE EITHER IMMEDIATELY OR AFTER ALLOWING THE VEHICLE SIT FOR A SHORT TIME, WHEREAS OTHERS REPORTED THAT THEY HAD THEIR VEHICLE TOWED.DURING PE05-029, ADDITIONAL FAILURE DATA WAS IDENTIFIED AS NOTED IN THE FAILURE REPORT SUMMARY ABOVE.THE COMPLAINT DATA REPRESENTS INCIDENTS WHERE ENGINE STALLING WAS ALLEGED OR WHERE THE VEHICLE WAS ALLEGED TO HAVE ONE OF THE VARIOUS CONDITIONS THAT CAUSES THE GAS ENGINE TO STALL.IN ITS AUGUST 26, 2005 RESPONSE TO ODI'S INFORMATION REQUEST, TOYOTA IDENTIFIED VARIOUS CONDITIONS THAT COULD CAUSE THE SUBJECT VEHICLES TO EXPERIENCE A GAS ENGINE STALL.IF THIS HAPPENS, THE DRIVER IS ALERTED BY AN AUDIBLE SOUND AND VARIOUS WARNING LIGHTS.THE VEHICLE WILL CONTINUE TO OPERATE IN THE ELECTRIC MODE AND THE ELECTRICALLY-POWERED BRAKE AND STEERING OPERATION WILL CONTINUE TO FUNCTION NORMALLY. ANALYSIS OF THE WARRANTY DATA INDICATED THAT OVER 97% OF VEHICLES EXPERIENCING A GAS ENGINE STALL RESULTED FROM AN ISSUE WITH THE PROGRAM LOGIC IN THE ELECTRONIC CONTROL MODULE (ECM) SYSTEM, WHICH MAY CAUSE THE ECM SYSTEM TO NOT START THE GAS ENGINE WHEN REQUIRED.AS A RESULT, THE VEHICLE WILL ENTER THE LIMITED OPERATION MODE DESCRIBED ABOVE.THE MAJORITY OF THE ODI COMPLAINTS ALSO INDICATED THAT THE DRIVER EXPERIENCED THIS CONDITION IN CONJUNCTION WITH THE ENGINE STALL. DURING OCTOBER 2005, TOYOTA INFORMED ODI THAT IT WOULD INITIATE A SPECIAL SERVICE CAMPAIGN (SSC) TO REPROGRAM THE ECM SOFTWARE ON APPROXIMATELY 75,000 MY 2004 AND EARLY 2005 SUBJECT VEHICLES TO ADDRESS THE GAS ENGINE STALLING CONDITION.DURING THIS SSC, DEALERS WILL ALSO APPLY SPECIAL DIELECTRIC GREASE TO A TRANSAXLE CONNECTOR TO PREVENT WATER INTRUSION WHICH MAY ALSO CAUSE SIMILAR LIMITED OPERATION CONDITIONS.BASED ON ODI'S ANALYSIS, THIS REMEDY SHOULD ADDRESS MOST OF THE INCIDENTS RESULTING IN A LIMITED OPERATION MODE.GIVEN THESE CIRCUMSTANCES, FURTHER USE OF THE AGENCY RESOURCES IN THIS MATTER DOES NOT APPEAR TO BE WARRANTED.ACCORDINGLY, THIS INVESTIGATION IS CLOSED.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT A SAFETY-RELATED DEFECT DOES NOT EXIST.THE AGENCY WILL CONTINUE TO MONITOR COMPLAINTS AND OTHER INFORMATION RELATING TO THE ALLEGED DEFECT IN THE SUBJECT VEHICLES AND TAKE FURTHER ACTION IN THE FUTURE IF WARRANTED.

Engine And Engine Cooling

ODI OPENED PE05-029 BASED ON 33 REPORTS OF ALLEGED GASOLINE ENGINE STALLING ON THE SUBJECT VEHICLES.THE SUBJECT VEHICLES ARE GASOLINE/ ELECTRIC HYBRID VEHICLES THAT CAN BE OPERATED IN GASOLINE OR ELECTRIC MODES, OR A COMBINATION OF BOTH DEPENDING ON THE POWER DEMAND.ALL REPORTS ALLEGE THAT THE GASOLINE ENGINE SHUT DOWN SUDDENLY WITHOUT WARNING.SOME OF THE COMPLAINANTS REPORTED THAT THE VEHICLE CONTINUED TO OPERATE USING THE ELECTRIC MODE FOR A PERIOD OF TIME AFTER THE GAS ENGINE STALLED AND SOME REPORTED THAT THE VEHICLE SHUT DOWN AT THE SAME TIME THAT THEY FELT THE GAS ENGINE STALLED.SOME CONSUMERS REPORTED THAT THEY WERE ABLE TO RESTART THE VEHICLE EITHER IMMEDIATELY OR AFTER ALLOWING THE VEHICLE SIT FOR A SHORT TIME, WHEREAS OTHERS REPORTED THAT THEY HAD THEIR VEHICLE TOWED.DURING PE05-029, ADDITIONAL FAILURE DATA WAS IDENTIFIED AS NOTED IN THE FAILURE REPORT SUMMARY ABOVE.THE COMPLAINT DATA REPRESENTS INCIDENTS WHERE ENGINE STALLING WAS ALLEGED OR WHERE THE VEHICLE WAS ALLEGED TO HAVE ONE OF THE VARIOUS CONDITIONS THAT CAUSES THE GAS ENGINE TO STALL.IN ITS AUGUST 26, 2005 RESPONSE TO ODI'S INFORMATION REQUEST, TOYOTA IDENTIFIED VARIOUS CONDITIONS THAT COULD CAUSE THE SUBJECT VEHICLES TO EXPERIENCE A GAS ENGINE STALL.IF THIS HAPPENS, THE DRIVER IS ALERTED BY AN AUDIBLE SOUND AND VARIOUS WARNING LIGHTS.THE VEHICLE WILL CONTINUE TO OPERATE IN THE ELECTRIC MODE AND THE ELECTRICALLY-POWERED BRAKE AND STEERING OPERATION WILL CONTINUE TO FUNCTION NORMALLY. ANALYSIS OF THE WARRANTY DATA INDICATED THAT OVER 97% OF VEHICLES EXPERIENCING A GAS ENGINE STALL RESULTED FROM AN ISSUE WITH THE PROGRAM LOGIC IN THE ELECTRONIC CONTROL MODULE (ECM) SYSTEM, WHICH MAY CAUSE THE ECM SYSTEM TO NOT START THE GAS ENGINE WHEN REQUIRED.AS A RESULT, THE VEHICLE WILL ENTER THE LIMITED OPERATION MODE DESCRIBED ABOVE.THE MAJORITY OF THE ODI COMPLAINTS ALSO INDICATED THAT THE DRIVER EXPERIENCED THIS CONDITION IN CONJUNCTION WITH THE ENGINE STALL. DURING OCTOBER 2005, TOYOTA INFORMED ODI THAT IT WOULD INITIATE A SPECIAL SERVICE CAMPAIGN (SSC) TO REPROGRAM THE ECM SOFTWARE ON APPROXIMATELY 75,000 MY 2004 AND EARLY 2005 SUBJECT VEHICLES TO ADDRESS THE GAS ENGINE STALLING CONDITION.DURING THIS SSC, DEALERS WILL ALSO APPLY SPECIAL DIELECTRIC GREASE TO A TRANSAXLE CONNECTOR TO PREVENT WATER INTRUSION WHICH MAY ALSO CAUSE SIMILAR LIMITED OPERATION CONDITIONS.BASED ON ODI'S ANALYSIS, THIS REMEDY SHOULD ADDRESS MOST OF THE INCIDENTS RESULTING IN A LIMITED OPERATION MODE.GIVEN THESE CIRCUMSTANCES, FURTHER USE OF THE AGENCY RESOURCES IN THIS MATTER DOES NOT APPEAR TO BE WARRANTED.ACCORDINGLY, THIS INVESTIGATION IS CLOSED.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT A SAFETY-RELATED DEFECT DOES NOT EXIST.THE AGENCY WILL CONTINUE TO MONITOR COMPLAINTS AND OTHER INFORMATION RELATING TO THE ALLEGED DEFECT IN THE SUBJECT VEHICLES AND TAKE FURTHER ACTION IN THE FUTURE IF WARRANTED.

Unknown Or Other

ODI OPENED PE05-029 BASED ON 33 REPORTS OF ALLEGED GASOLINE ENGINE STALLING ON THE SUBJECT VEHICLES.THE SUBJECT VEHICLES ARE GASOLINE/ ELECTRIC HYBRID VEHICLES THAT CAN BE OPERATED IN GASOLINE OR ELECTRIC MODES, OR A COMBINATION OF BOTH DEPENDING ON THE POWER DEMAND.ALL REPORTS ALLEGE THAT THE GASOLINE ENGINE SHUT DOWN SUDDENLY WITHOUT WARNING.SOME OF THE COMPLAINANTS REPORTED THAT THE VEHICLE CONTINUED TO OPERATE USING THE ELECTRIC MODE FOR A PERIOD OF TIME AFTER THE GAS ENGINE STALLED AND SOME REPORTED THAT THE VEHICLE SHUT DOWN AT THE SAME TIME THAT THEY FELT THE GAS ENGINE STALLED.SOME CONSUMERS REPORTED THAT THEY WERE ABLE TO RESTART THE VEHICLE EITHER IMMEDIATELY OR AFTER ALLOWING THE VEHICLE SIT FOR A SHORT TIME, WHEREAS OTHERS REPORTED THAT THEY HAD THEIR VEHICLE TOWED.DURING PE05-029, ADDITIONAL FAILURE DATA WAS IDENTIFIED AS NOTED IN THE FAILURE REPORT SUMMARY ABOVE.THE COMPLAINT DATA REPRESENTS INCIDENTS WHERE ENGINE STALLING WAS ALLEGED OR WHERE THE VEHICLE WAS ALLEGED TO HAVE ONE OF THE VARIOUS CONDITIONS THAT CAUSES THE GAS ENGINE TO STALL.IN ITS AUGUST 26, 2005 RESPONSE TO ODI'S INFORMATION REQUEST, TOYOTA IDENTIFIED VARIOUS CONDITIONS THAT COULD CAUSE THE SUBJECT VEHICLES TO EXPERIENCE A GAS ENGINE STALL.IF THIS HAPPENS, THE DRIVER IS ALERTED BY AN AUDIBLE SOUND AND VARIOUS WARNING LIGHTS.THE VEHICLE WILL CONTINUE TO OPERATE IN THE ELECTRIC MODE AND THE ELECTRICALLY-POWERED BRAKE AND STEERING OPERATION WILL CONTINUE TO FUNCTION NORMALLY. ANALYSIS OF THE WARRANTY DATA INDICATED THAT OVER 97% OF VEHICLES EXPERIENCING A GAS ENGINE STALL RESULTED FROM AN ISSUE WITH THE PROGRAM LOGIC IN THE ELECTRONIC CONTROL MODULE (ECM) SYSTEM, WHICH MAY CAUSE THE ECM SYSTEM TO NOT START THE GAS ENGINE WHEN REQUIRED.AS A RESULT, THE VEHICLE WILL ENTER THE LIMITED OPERATION MODE DESCRIBED ABOVE.THE MAJORITY OF THE ODI COMPLAINTS ALSO INDICATED THAT THE DRIVER EXPERIENCED THIS CONDITION IN CONJUNCTION WITH THE ENGINE STALL. DURING OCTOBER 2005, TOYOTA INFORMED ODI THAT IT WOULD INITIATE A SPECIAL SERVICE CAMPAIGN (SSC) TO REPROGRAM THE ECM SOFTWARE ON APPROXIMATELY 75,000 MY 2004 AND EARLY 2005 SUBJECT VEHICLES TO ADDRESS THE GAS ENGINE STALLING CONDITION.DURING THIS SSC, DEALERS WILL ALSO APPLY SPECIAL DIELECTRIC GREASE TO A TRANSAXLE CONNECTOR TO PREVENT WATER INTRUSION WHICH MAY ALSO CAUSE SIMILAR LIMITED OPERATION CONDITIONS.BASED ON ODI'S ANALYSIS, THIS REMEDY SHOULD ADDRESS MOST OF THE INCIDENTS RESULTING IN A LIMITED OPERATION MODE.GIVEN THESE CIRCUMSTANCES, FURTHER USE OF THE AGENCY RESOURCES IN THIS MATTER DOES NOT APPEAR TO BE WARRANTED.ACCORDINGLY, THIS INVESTIGATION IS CLOSED.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT A SAFETY-RELATED DEFECT DOES NOT EXIST.THE AGENCY WILL CONTINUE TO MONITOR COMPLAINTS AND OTHER INFORMATION RELATING TO THE ALLEGED DEFECT IN THE SUBJECT VEHICLES AND TAKE FURTHER ACTION IN THE FUTURE IF WARRANTED.