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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
159,600 miles · Feb 21, 2012
Exterior Lighting

I WAS DRIVING AT NIGHT ON A NARROW COUNTRY ROAD, LINED WITH TREES, AT 55 MPH. SUDDENLY , BOTH HEAD LAMPS SHUT OFF. IT IS A MIRACLE THAT I DIDN'T WRECK, I COULD NOT SEE A THING, AND BRAKED BLINDLY. AS I WAS COMING TO A STOP I TURNED THE LIGHT SWITCH ON AND OFF AND THE LIGHTS CAME BACK ON. BEFORE I COULD GET HOME, THE LIGHTS WENT …

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I WAS DRIVING AT NIGHT ON A NARROW COUNTRY ROAD, LINED WITH TREES, AT 55 MPH. SUDDENLY , BOTH HEAD LAMPS SHUT OFF. IT IS A MIRACLE THAT I DIDN'T WRECK, I COULD NOT SEE A THING, AND BRAKED BLINDLY. AS I WAS COMING TO A STOP I TURNED THE LIGHT SWITCH ON AND OFF AND THE LIGHTS CAME BACK ON. BEFORE I COULD GET HOME, THE LIGHTS WENT OFF 2 MORE TIMES! *TR

NHTSA ODI #10448866

112,000 miles · Feb 15, 2012
Exterior Lighting

INTERMITTENT HEADLIGHT PROBLEM. I PURCHASED THE CAR WITH 111,500 MILES ON IT, AND ALMOST IMMEDIATELY NOTICED THAT THE PASSENGER'S SIDE HEADLIGHT IS INTERMITTENT WHEN VIEWING MY REFLECTION IN THE BUMPER OF THE CAR IN FRONT OF ME. SOMETIMES IT RUNS FINE FOR OVER AN HOUR, OTHER TIMES IT DOESN'T LAST 5 MINUTES. TURNING THE HEADLIGHT…

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INTERMITTENT HEADLIGHT PROBLEM. I PURCHASED THE CAR WITH 111,500 MILES ON IT, AND ALMOST IMMEDIATELY NOTICED THAT THE PASSENGER'S SIDE HEADLIGHT IS INTERMITTENT WHEN VIEWING MY REFLECTION IN THE BUMPER OF THE CAR IN FRONT OF ME. SOMETIMES IT RUNS FINE FOR OVER AN HOUR, OTHER TIMES IT DOESN'T LAST 5 MINUTES. TURNING THE HEADLIGHTS OFF, AND IMMEDIATELY BACK ON RELIGHTS THE HEADLIGHT. THIS IS NOT ONLY HAPPENING AT NIGHT, BUT ALSO DURING THE DAY WHEN THEY ARE USED AS DAYTIME RUNNING LIGHTS. I MADE A VIDEO OF IT HAPPENING: HTTP://TINYURL.COM/INTERMITTENTPRIUSHID I AM NOT THE ONLY PERSON HAVING THIS PROBLEM WITH THEIR PRIUS. OTHERS HAVE REPORTED THIS PROBLEM WITH 25,000 TO 40,000 MILES. IT IS VERY HARD TO NOTICE BECAUSE THE HID HEADLIGHTS ARE SO BRIGHT IT IS HARD TO TELL WHEN ONE IS NOT WORKING, WHICH ACTUALLY MEANS THIS PROBLEM MAY HAVE EXISTED ON MY PRIUS FOR A LONG TIME WITHOUT THE PREVIOUS OWNER NOTICING. TO ILLUSTRATE MY POINT, THIS PRIUSCHAT THREAD HAS OVER 870 RESPONSES TO DATE REGARDING THIS HID HEADLIGHT PROBLEM: HTTP://PRIUSCHAT.COM/FORUMS/GEN-II-PRIUS-CARE-MAINTENANCE-TROUBLESHOOTING/34584-HEADLIGHT-PROBLEM-17.HTML THUS FAR I HAVE NOT NOTICED THIS PROBLEM IN MY DRIVER'S SIDE. THIS IS A VERY REAL SAFETY CONCERN. *TR

NHTSA ODI #10448018

Mileage unknown · Feb 14, 2012
Electrical SystemVehicle Speed Control

2004 TOYOTA PRIUS. CONSUMER STATES UNINTENDED ACCELERATION *TGW THE CONSUMER STATED THE SUDDEN ACCELERATION HAPPENED THREE TIMES, OVER A SIX YEAR SPAN. HE MANAGED TO PUT THE VEHICLE IN NEUTRAL, COAST TO THE SIDE OF THE ROAD, AND TURNED THE VEHICLE OFF. ONCE THE VEHICLE WAS RESTARTED, ALL WORKED FINE. THE CONSUMER STATED A FEW…

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2004 TOYOTA PRIUS. CONSUMER STATES UNINTENDED ACCELERATION *TGW THE CONSUMER STATED THE SUDDEN ACCELERATION HAPPENED THREE TIMES, OVER A SIX YEAR SPAN. HE MANAGED TO PUT THE VEHICLE IN NEUTRAL, COAST TO THE SIDE OF THE ROAD, AND TURNED THE VEHICLE OFF. ONCE THE VEHICLE WAS RESTARTED, ALL WORKED FINE. THE CONSUMER STATED A FEW WEEKS AGO HIS VEHICLE WAS ABOUT TO REACH 300,000 MILES, AS HE REACHED FOR HIS CAMERA, HE REALIZED THE ODOMETER NEVER WENT PAST 299,999 MILES. HOWEVER, WITHIN FIVE MILES, THE VEHICLE SUDDENLY LOST POWER BRAKES, THE AIR CONDITION STOPPED WORKING, THE HYBRID DRIVE SHUT OFF AND THE FAN FOR THE HYBRID BATTERY CAME ON, AS WELL AS YELLOW AND RED LIGHTS APPEARED ON THE DASH. ALSO, TWO WARNING GRAPHICS APPEARED ON THE NAVIGATION SCREEN, ONE INDICATING TROUBLE. THE CONSUMER PULLED OVER, AND SHUT THE ENGINE OFF. HE THEN RESTARTED THE VEHICLE AND EVERYTHING WENT BACK TO NORMAL. IT APPEARED THAT BY SHUTTING OFF THE ENGINE AND RESTARTING IT, CAUSED THE MAIN COMPUTER REBOOT. THE CONSUMER STATED IT CONTINUED SEVERAL MORE TIMES, UNTIL HE ARRIVED HOME. THE DEALER INFORMED THE CONSUMER THE VEHICLE WAS A LARGE COMPUTER, AND WHEN ONE COMPONENT STOPS WORKING, SUCH AS THE ODOMETER, OTHER COMPONENTS CEASE TOO. THE DEALER EXPLAINED AN ODOMETER LIMIT WAS PLACED ON THE VEHICLE BY THE FACTORY. *JB

NHTSA ODI #10447642

118,000 miles · Feb 13, 2012
Exterior Lighting

HEADLIGHTS DONT WORK, OVERHEATING BULBS $800 TO REPLACE, YOU GO TOYOTA YOUR CAR SUCKS. *TR

NHTSA ODI #10447826

90,000 miles · Feb 3, 2012
Exterior Lighting

TL* THE CONTACT OWNS A 2004 TOYOTA PRIUS. THE CONTACT WAS DRIVING 35 MPH WHEN BOTH HEADLIGHTS FAILED INTERMITTENTLY. THE VEHICLE WAS TAKEN TO THE DEALER WHO CONFIRMED THAT THE BALLAST FAILED FOR THE HEADLIGHTS. THE MANUFACTURER WAS CONTACTED BUT THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS 90,000 AND THE CURRENT MILEAGE…

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TL* THE CONTACT OWNS A 2004 TOYOTA PRIUS. THE CONTACT WAS DRIVING 35 MPH WHEN BOTH HEADLIGHTS FAILED INTERMITTENTLY. THE VEHICLE WAS TAKEN TO THE DEALER WHO CONFIRMED THAT THE BALLAST FAILED FOR THE HEADLIGHTS. THE MANUFACTURER WAS CONTACTED BUT THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS 90,000 AND THE CURRENT MILEAGE WAS 96,000.

NHTSA ODI #10446398

80,000 miles · Jan 28, 2012
Electrical SystemExterior Lighting

THE HID HEADLIGHT LEVELING SENSOR PART# 89408-47010 FAILED. BIG RED EXCLAMATION ON THE DASH AND CAR WON'T PASS INSPECTION. TOYOTA SAYS IT COSTS $600 TO REPLACE. *TR

NHTSA ODI #10445658

160,000 miles · Jan 19, 2012
Electrical SystemVehicle Speed Control

WHEN AMBIENT TEMPERATURE IS COLD, SOMETIMES DASHBOARD LIGHTS AND SPEEDOMETER DO NOT COME ON WHEN THE CAR IS STARTED. CAR RUNS BUT WITH NO INSTRUMENT PANEL. SOMETIMES WHEN THE CAR IS IN THIS STATE THE CAR CANNOT BE TURNED OFF BY PRESSING THE START BUTTON. CAR CAN ONLY BE TURNED OFF BY PRESSING AND HOLDING THE START BUTTON DOWN FO…

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WHEN AMBIENT TEMPERATURE IS COLD, SOMETIMES DASHBOARD LIGHTS AND SPEEDOMETER DO NOT COME ON WHEN THE CAR IS STARTED. CAR RUNS BUT WITH NO INSTRUMENT PANEL. SOMETIMES WHEN THE CAR IS IN THIS STATE THE CAR CANNOT BE TURNED OFF BY PRESSING THE START BUTTON. CAR CAN ONLY BE TURNED OFF BY PRESSING AND HOLDING THE START BUTTON DOWN FOR SEVERAL SECONDS, AND EVEN THIS DOES NOT ALWAYS WORK. THIS PROBLEM HAS BEEN GETTING WORSE OVER TIME. TOYOTA DEALERSHIP REFUSES TO INVESTIGATE THE PROBLEM, BUT IT IS DOCUMENTED IN THEIR WARRANTY REPAIR T-SB-0172-09 COMBINATION METER INTERMITTENT DISPLAY BULLETIN. INSTEAD, THE DEALERSHIP TRIES TO SELL US A NEW CAR! *TT

NHTSA ODI #10444588

41,520 miles · Jan 5, 2012
Visibility

THE MULTI FUNCTION DISPLAY REGISTERED THE ERROR CODE: CHECK CONNECTION OF AIR CONDITIONER. A DIAGNOSTIC TEST AT PAPPAS TOYOTA ON 12/2/11 SHOWED A DEFECTIVE MFD. A NEW REPLACEMENT WOULD COST $4300. A REFURBISHED ONE WAS TO BE LOCATED BUT A CALL WAS NOT RECEIVED AS TO THIS HAVING HAPPENED. TOYOTA WAS AWARE OF THIS POSSIBILITY A…

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THE MULTI FUNCTION DISPLAY REGISTERED THE ERROR CODE: CHECK CONNECTION OF AIR CONDITIONER. A DIAGNOSTIC TEST AT PAPPAS TOYOTA ON 12/2/11 SHOWED A DEFECTIVE MFD. A NEW REPLACEMENT WOULD COST $4300. A REFURBISHED ONE WAS TO BE LOCATED BUT A CALL WAS NOT RECEIVED AS TO THIS HAVING HAPPENED. TOYOTA WAS AWARE OF THIS POSSIBILITY AT LEAST BY 1/10/2005 WHEN A SERVICE BULLETIN WAS ISSUED. SINCE THE DEFECT IN THE PART WAS KNOWN TO TOYOTA AND INVOLVES A SAFETY ISSUE A REQUEST FOR WARRANTY REPLACEMENT WAS MADE. THIS REQUEST WAS DENIED. ON 12/23/11, AFTER HAVING BEEN TOLD A WEEK WOULD BE NEEDED TO FIND THE PART, I E-MAILED PAPPAS AND ASKED THAT ONE BE LOCATED. I MADE AN APPT. AT THAT TIME TO HAVE IT INSTALLED ON 1/3/12. I HAD NOT RECEIVED ANY INFORMATION BY 1/2/12 SO I CALLED AGAIN AND LEARNED THE PART WAS TO BE ORDERED ON 1/2/12 AS TOYOTA WAS CLOSED FOR THE HOLIDAY PERIOD. THE MFD ACTIVATES THE FRONT AND REAR DEFROSTERS. THIS IS CRITICAL AS THE INABILITY TO DO SO IS A SAFETY ISSUE IN MISSOURI WITH SNOW AND ICE BEING A POSSIBILITY. ON 1/4/12 A MESSAGE WAS RECEIVED FROM THE DEALERSHIP, THE ESSENCE OF WHICH WAS: THOSE DISPLAYS ARE ON BACK ORDER STATUS AT THIS TIME; THE MFD HOLDS THE MEMORY FOR THE MILEAGE ODOMETER SO WHEN IT IS ORDERED THE VEHICLE CAN NOT BE DRIVEN SO THAT THE ACTUAL ODOMETER MILEAGE REMAINS THE SAME; AND UNTIL I HEAR FROM YOU I HAVE PLACED YOUR ORDER ON HOLD; THERE ARE CURRENTLY TWO ORDERS AHEAD OF YOURS AND THEY WILL BE FILLED FIRST; THEY ARE NOT ABLE TO GIVE US A TIMETABLE WHEN THEY WILL BE RELEASED; AND ONCE THEY ARE AVAILABLE IT WILL TAKE APPROXIMATELY 7-10 BUSINESS DAYS TO RECEIVE. TOYOTA IS NOT MAKING THE NECESSARY PART AVAILABLE; EXPECTING THE CONSUMER TO BE DEPRIVED OF USE OF THE PRIUS FOR AN UNDETERMINED PERIOD OF TIME; AND OF BEARING THE COST OF THE DEFECTIVE PART. THE CONSUMER STATED THE PROBLEM HAS BEEN RESOLVED. UPDATED IVOQ 03/09/12 *TR

NHTSA ODI #10442546

193,000 miles · Dec 9, 2011
Air BagsCrashInjury

2004 TOYOTA PRIUS FRONTAL IMPACT CRASH INTO REAR OF VEHICLE 2, 2002 HONDA CRV, ON TUESDAY NOVEMBER 22, 2011, 4:33PM EST. BUMPER IMPACT AT APPROX SPEED 25MPH IN CLEAR CONDITIONS TOTALED SUBJECT VEHICLE INCLUDING COMPLETE FOLDING OF HOOD, DISPLACEMENT OF STRUCTURAL BUMPER, FAN ASSEMBLIES, RADIATOR & CONDENSER ASSEMBLIES INTO ENG…

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2004 TOYOTA PRIUS FRONTAL IMPACT CRASH INTO REAR OF VEHICLE 2, 2002 HONDA CRV, ON TUESDAY NOVEMBER 22, 2011, 4:33PM EST. BUMPER IMPACT AT APPROX SPEED 25MPH IN CLEAR CONDITIONS TOTALED SUBJECT VEHICLE INCLUDING COMPLETE FOLDING OF HOOD, DISPLACEMENT OF STRUCTURAL BUMPER, FAN ASSEMBLIES, RADIATOR & CONDENSER ASSEMBLIES INTO ENGINE WITH STRUCTURAL BUMPER PUSHED BACK 24" AT CENTER AND 18" TO LEFT & RIGHT SIDES. INSURANCE ADJUSTER STATED THAT BENDING OCCURRED AT FRONT OF VEHICLE FRAME. FRONT FENDERS CRUMPLED AND OBSTRUCTED FRONT DRIVER AND PASSENGER DOORS, ENTRAPPING OCCUPANTS, BOTH SEAT-BELTED INTO FRONT SEATS. DESPITE DISPLACEMENT FRONT STRUCTURAL BUMPER ASSEMBLY, BODY AND FRONT MECHANICALS, AIRBAGS DID NOT DEPLOY. SUBJECT AUTOMOBILE WAS HIGHER-MILEAGE VEHICLE WITH 193,000 MILES BUT IMMACULATELY MAINTAINED, RELIABLE, MECHANICALLY EXCELLENT, DISPLAYING NO SYSTEM WARNING LIGHTS AND HAVING NEWER MICHELIN RADIAL TIRES WITH 25% WEAR. OWNER HAS FULL SET OF PHOTOGRAPHS. EXTERIOR & INTERIOR, ATTESTING CLEAN CONDITION OF CAR AND FULL SET OF VEHICLE MAINTENANCE RECORDS. CRASH RESULTED IN MODERATE INJURY TO OCCUPANTS, MAINLY BRUISING, CONTUSIONS, BACK & NECK PAIN. BOTH WERE ADMITTED TO HOSPITAL ER AND DISCHARGED SAME DAY. FOLLOW UP MEDICAL CARE ONGOING. CONCERNED ABOUT AIRBAG-NON-DEPLOYMENT. BELIEVING THIS TO BE A FAILURE OF THE CAR'S SUPPLEMENTAL RESTRAINT SYSTEM. MY DAUGHTER AND WIFE'S INJURIES ARE NOT CRIPPLING OR DISFIGURING BUT IN SIMILAR CRASHES, WOULD OTHERS FAIR AS WELL? INCIDENT AND CONCERNS REGISTERED WITH TOYOTA CORPORATE, WHICH ASSERTED THAT AIRBAGS FUNCTIONED (?) AS DESIGNED. NOT SURPRISED THAT THEIR FIRST PRIORITY WOULD BE PROTECTING THEIR CORPORATED HIND QUARTERS BUT BELIEVE THAT NHTSA MIGHT PERFORM A MORE OBJECTIVE INVESTIGATION INTO THE HISTORY AND PERFORMANCE EFFICACY OF PRIUS AIRBAGS. THANK YOU. *TR

NHTSA ODI #10439142

87,691 miles · Dec 1, 2011
Power Train

TL* THE CONTACT OWNS A 2004 TOYOTA PRIUS. THE CONTACT STATED THAT THE GEAR SHIFTED FROM DRIVE INTO NEUTRAL SEVERAL TIMES INDEPENDENTLY. THE CONTACT HAD TO HOLD THE GEAR FOR IT TO REMAIN IN DRIVE. THE VEHICLE WAS TAKEN TO THE DEALER WHO PERFORMED A DIAGNOSTIC. THE FAILURE WAS LOCATED AT THE GEAR SHIFTER. THE VEHICLE WAS NOT REPAI…

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TL* THE CONTACT OWNS A 2004 TOYOTA PRIUS. THE CONTACT STATED THAT THE GEAR SHIFTED FROM DRIVE INTO NEUTRAL SEVERAL TIMES INDEPENDENTLY. THE CONTACT HAD TO HOLD THE GEAR FOR IT TO REMAIN IN DRIVE. THE VEHICLE WAS TAKEN TO THE DEALER WHO PERFORMED A DIAGNOSTIC. THE FAILURE WAS LOCATED AT THE GEAR SHIFTER. THE VEHICLE WAS NOT REPAIRED AND THE MANUFACTURER WAS MADE AWARE OF THE FAILURE, BUT DENIED ASSISTANCE WITH THE REPAIR. THE FAILURE AND THE CURRENT MILEAGE WAS 87,691.

NHTSA ODI #10437999

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.