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2005 Toyota Prius

Owner reports · Recalls · Investigations

More warning signs than most Prius years

Owner complaints for the 2005 Toyota Prius are substantially higher than the model-year median of 164.

About this comparison →

When problems were reported

Mileage at the reported incident

871 reports with mileage · 180 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 346 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Electrical System. Review the 178 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Service Brakes, Hydraulic. Review the 128 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →

NHTSA owner reports · September 18, 2026 snapshot.

102 crash reports4 fire reports46 injury reports

Exterior Lighting complaints

346 reports
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69,000 miles · Sep 12, 2011
Exterior Lighting

TL* THE CONTACT OWNS A 2005 TOYOTA PRIUS. THE CONTACT WAS DRIVING APPROXIMATELY 65 MPH WITH THE HEADLIGHTS ACTIVATED AND SUDDENLY THE DRIVER'S SIDE HEADLIGHT CHANGED TO AN ORANGE ILLUMINATION AND THEN BECAME INOPERATIVE WHICH RESULTED IN THE REDUCTION IN VISIBILITY. WHEN THE LIGHT SWITCH WAS TURNED ON AND OFF REPEATEDLY THE DRIV…

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TL* THE CONTACT OWNS A 2005 TOYOTA PRIUS. THE CONTACT WAS DRIVING APPROXIMATELY 65 MPH WITH THE HEADLIGHTS ACTIVATED AND SUDDENLY THE DRIVER'S SIDE HEADLIGHT CHANGED TO AN ORANGE ILLUMINATION AND THEN BECAME INOPERATIVE WHICH RESULTED IN THE REDUCTION IN VISIBILITY. WHEN THE LIGHT SWITCH WAS TURNED ON AND OFF REPEATEDLY THE DRIVER'S SIDE HEADLIGHTS BEGAN TO ILLUMINATE PROPERLY FOR A BRIEF MOMENT. THE VEHICLE WAS NOT REPAIRED NOR WAS THE FAILURE DIAGNOSED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 69,000.

NHTSA ODI #10424712

Mileage unknown · Sep 6, 2011
Exterior Lighting

DRIVERS SIDE HID HEADLIGHT INTERMITTANT OPERATION. HEADLAMP GOES ON AND OFF AT VARIOUS TIMES IN TRAFFIC AT NIGHT. *TR

NHTSA ODI #10423844

150,000 miles · Aug 22, 2011
Exterior Lighting

TL* THE CONTACT OWNS A 2005 TOYOTA PRIUS. THE CONTACT STATED THAT THE HEADLIGHTS FAILED WITHOUT WARNING. THE CONTACT SPOKE WITH THE MANUFACTURER AND WAS TOLD THAT THE BULBS MOST LIKELY CAUSED THE FAILURE. THE HEADLIGHT BULBS WERE REPLACED BUT TO NO AVAIL. THE CONTACT SPOKE WITH THE MANUFACTURER A SECOND TIME AND WAS TOLD THAT TH…

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TL* THE CONTACT OWNS A 2005 TOYOTA PRIUS. THE CONTACT STATED THAT THE HEADLIGHTS FAILED WITHOUT WARNING. THE CONTACT SPOKE WITH THE MANUFACTURER AND WAS TOLD THAT THE BULBS MOST LIKELY CAUSED THE FAILURE. THE HEADLIGHT BULBS WERE REPLACED BUT TO NO AVAIL. THE CONTACT SPOKE WITH THE MANUFACTURER A SECOND TIME AND WAS TOLD THAT THE COMPUTER WHICH OPERATED EACH HEADLIGHT COULD POSSIBLY NEED REPLACING. THAT VEHICLE WAS NOT REPAIRED. THE VIN WAS NOT AVAILABLE. THE FAILURE MILEAGE WAS 150,000 AND THE CURRENT MILEAGE WAS 158,000.

NHTSA ODI #10420926

167,000 miles · Aug 21, 2011
Exterior Lighting

WHEN DRIVING AT VARIOUS SPEEDS, ONE OR BOTH OF THE HID HEADLIGHTS WILL GO OUT. IF I TURN THEM ALL THE WAY OFF, THEN BACK ON, THEY WILL LIGHT UP, BUT MAY GO OUT AGAIN OR MAY STAY LIT. THE VEHICLE IS A 2005 TOYOTA PRIUS WITH HID HEADLIGHTS. NOTE: THE HEADLIGHTS WILL NOT RELIGHT ON THEIR OWN; THEY MUST BE TURNED OFF THEN BACK ON. *…

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WHEN DRIVING AT VARIOUS SPEEDS, ONE OR BOTH OF THE HID HEADLIGHTS WILL GO OUT. IF I TURN THEM ALL THE WAY OFF, THEN BACK ON, THEY WILL LIGHT UP, BUT MAY GO OUT AGAIN OR MAY STAY LIT. THE VEHICLE IS A 2005 TOYOTA PRIUS WITH HID HEADLIGHTS. NOTE: THE HEADLIGHTS WILL NOT RELIGHT ON THEIR OWN; THEY MUST BE TURNED OFF THEN BACK ON. *TR

NHTSA ODI #10420882

36,000 miles · Aug 19, 2011
Exterior Lighting

THE HEADLIGHT LEVELING CONTROL WARNING SIGNAL CAME ONE, THE CAR HAS ONLY 36000 MILES. THIS IS A VERY EXPENSIVE FIX AND HAS SAFETY ISSUES, AND APPEARS TO BE A DEFECT ON MANY SIMILAR MODELS. *TR

NHTSA ODI #10420771

97,650 miles · Aug 16, 2011
Exterior Lighting

WHILE DRIVING MY 2005 TOYOTA PRIUS ON AN EXPRESSWAY AT NIGHT THE PASSENGER SIDE HEADLIGHT WENT OUT. THERE WAS NO LIGHTS ON THE EXPRESSWAY AND I NEARLY HIT A PARKED CAR ON THE SIDE OF THE EXPRESSWAY. I PULLED OVER AT THE NEXT EXIT AND CHECKED THE HEADLIGHTS. THE PASSENGER HEADLIGHT WAS INDEED OUT. I TURNED THE CAR OFF AND WENT IN…

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WHILE DRIVING MY 2005 TOYOTA PRIUS ON AN EXPRESSWAY AT NIGHT THE PASSENGER SIDE HEADLIGHT WENT OUT. THERE WAS NO LIGHTS ON THE EXPRESSWAY AND I NEARLY HIT A PARKED CAR ON THE SIDE OF THE EXPRESSWAY. I PULLED OVER AT THE NEXT EXIT AND CHECKED THE HEADLIGHTS. THE PASSENGER HEADLIGHT WAS INDEED OUT. I TURNED THE CAR OFF AND WENT INTO THE RESTROOM. WHEN I CAME OUT AND RESTARTED THE CAR THE HEADLIGHT WAS ON. FIVE MINUTES LATER THE HEADLIGHT WENT OUT AGAIN. I TURNED THE LIGHTS OFF, THEN ON AGAIN AND IT CAME BACK ON. THIS HAPPENED AT LEAST TWENTY TIMES DURING THE FOUR HOUR TRIP HOME. SCARY AND DANGEROUS IN MY BOOK. *KB

NHTSA ODI #10419598

85,000 miles · Aug 5, 2011
Exterior LightingUnknown Or OtherVehicle Speed Control

ON 7/31/11 I NOTICED MY CRUISE CONTROL WOULD NOT SET. THE LIGHT CAME ON INDICATING THE CRUISE WAS ON, BUT I COULD NOT GET THE SPEED TO HOLD. THE NEXT DAY, THE CRUISE CONTROL WORKED. MIDDAY ON 8/1/11 WHILE PARKED, I SHIFTED TO THE D POSITION, BUT THE LIGHT INDICATED I WAS IN N. I SHIFTED BACK AND FORTH BETWEEN R AND D SEVER…

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ON 7/31/11 I NOTICED MY CRUISE CONTROL WOULD NOT SET. THE LIGHT CAME ON INDICATING THE CRUISE WAS ON, BUT I COULD NOT GET THE SPEED TO HOLD. THE NEXT DAY, THE CRUISE CONTROL WORKED. MIDDAY ON 8/1/11 WHILE PARKED, I SHIFTED TO THE D POSITION, BUT THE LIGHT INDICATED I WAS IN N. I SHIFTED BACK AND FORTH BETWEEN R AND D SEVERAL TIMES, BUT THE LIGHT INDICATED N. I TOOK MY FOOT OFF THE BRAKE AND THE CAR MOVED BACKWARD. THE LIGHT INDICATED N AND THE KNOB WAS IN THE D POSITION. IT DID THIS SEVERAL TIMES. I TURNED THE CAR OFF AND BACK ON AND EVERYTHING WORKED LIKE IT IS SUPPOSED TO. ON 8/1/11 AT APPROXIMATELY 10:30 P.M. I WAS DRIVING HOME ON A NARROW, TWO-LANE RURAL HIGHWAY. ON A BLIND CURVE, BOTH OF MY HEADLIGHTS WENT OUT. I COULD NOT SEE ANYTHING. I TRIED CYCLING MY HEADLIGHTS OFF AND ON AND NOTHING HAPPENED. I APPLIED MY BRAKES AND STOPPED. I OPENED MY DOOR TO SEE WHERE I WAS IN THE ROADWAY AND DETERMINED I WAS ON THE FOG LINE ON THE OPPOSITE SIDE OF THE ROAD AND THERE WAS A HILLSIDE LESS THAN 5' FROM ME. I WAS ABLE TO DRIVE TO THE SHOULDER ON THE RIGHT SIDE OF THE ROAD BY USING THE LIGHT FROM MY DOOR. I WAS EXTREMELY LUCKY NO CARS PASSED BY WHILE MY LIGHTS WERE OUT. I COULD HAVE BEEN KILLED OR CAUSED A CATASTROPHE. I TURNED THE CAR OFF AND BACK ON AND BOTH HEADLIGHTS CAME BACK ON. A MOTORIST STOPPED TO ASSIST. I WAS ABLE TO FOLLOW HIM TO A STORE WHERE A FRIEND MET ME AND I FOLLOWED HIM HOME. DURING THE DRIVE HOME ONE OF MY HEADLIGHTS KEPT TURNING OFF. BOTH DID NOT GO OFF TOGETHER AGAIN. I TOOK THE CAR TO THE DEALER ON 8/3/11 AND WAS TOLD I NEED A NEW AUXILIARY BATTERY AND TWO NEW HEADLIGHTS. COST IS GOING TO BE AROUND $700. I READ ABOUT A CLASS ACTION SUIT REGARDING 2006-2009 PRIUS' HEADLIGHTS AND THAT TOYOTA KNOWS THERE IS A PROBLEM WITH THEM. I BELIEVE THERE SHOULD BE A RECALL BECAUSE OF MY HARROWING EXPERIENCE AND THOSE OF MANY OTHERS.

NHTSA ODI #10417568

126,000 miles · Jul 27, 2011
Exterior Lighting

I HAVE A 2005 TOYOTA PRIUS WITH HID HEADLIGHTS. THEY BEGAN FAILING, FIRST IT WAS ONLY THE DRIVERS SIDE LIGHT, AND INFREQUENTLY. I FOUND THAT WHEN I TURNED THE LIGHTS OFF AND ON AGAIN, THE HEADLIGHT WORKED AGAIN. BECAUSE OF THE HIGH COST OF REPLACEMENT, I LIVED WITH THE PROBLEM. RECENTLY, BOTH LIGHTS FAILED ON A BACK COUNTRY CURV…

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I HAVE A 2005 TOYOTA PRIUS WITH HID HEADLIGHTS. THEY BEGAN FAILING, FIRST IT WAS ONLY THE DRIVERS SIDE LIGHT, AND INFREQUENTLY. I FOUND THAT WHEN I TURNED THE LIGHTS OFF AND ON AGAIN, THE HEADLIGHT WORKED AGAIN. BECAUSE OF THE HIGH COST OF REPLACEMENT, I LIVED WITH THE PROBLEM. RECENTLY, BOTH LIGHTS FAILED ON A BACK COUNTRY CURVY ROAD. FOR AN INSTANT EVERYTHING WAS TOTALLY BLACK. I QUICKLY TURNED THE LIGHTS OFF AND ON AND WAS ABLE TO SWERVE TO GET BACK ON THE ROAD. AS A RESULT, I AM GOING TO HAVE TO PAY NEARLY $1,000 TO HAVE BOTH HEADLIGHTS REPLACED AT MY EXPENSE, SINCE I HAD MORE THAN 50,000 MILES ON MY PRIUS. TOYOTA CUSTOMER CARE TOLD ME THAT I WOULD NOT BE COVERED BY A CLASS ACTION CASE FOR THE HID BULB REPLACEMENT BECAUSE MY CAR IS A 2005 AND IS NOT COVERED IN THE CASE. THIS IS A SAFETY ISSUE AND SHOULD BE A RECALL. *TR

NHTSA ODI #10415353

Mileage unknown · Jul 26, 2011
Electrical SystemExterior Lighting

PASSENGER FRONT HID HEADLIGHT WAS INTERMEDIATELY OPERATIONAL FOR A SHORT PERIOD OF TIME. EVENTUALLY IT WOULD NOT COME BACK ON. TOYOTA DEALER QUOTED $350+ FOR PART AND $150+ FOR LABOR, PER HEADLIGHT. ACCORDING TO OTHER PRIUS OWNERS AND INTERNET ARTICLES, THIS ISSUE IS APPARENT TO BE A MANUFACTURER DEFECT; BUT TOYOTA REFUSES TO …

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PASSENGER FRONT HID HEADLIGHT WAS INTERMEDIATELY OPERATIONAL FOR A SHORT PERIOD OF TIME. EVENTUALLY IT WOULD NOT COME BACK ON. TOYOTA DEALER QUOTED $350+ FOR PART AND $150+ FOR LABOR, PER HEADLIGHT. ACCORDING TO OTHER PRIUS OWNERS AND INTERNET ARTICLES, THIS ISSUE IS APPARENT TO BE A MANUFACTURER DEFECT; BUT TOYOTA REFUSES TO ADMIT IN ORDER TO PREVENT A RECALL. UNWILLING TO PAID FOR TOYOTA'S MISTAKES, THE VEHICLE WAS DRIVEN WITH ONLY ONE HEADLIGHT FOR SOME TIME. UNTIL RECENTLY STOPPED BY POLICE AND ISSUED A TRAFFIC VIOLATION WARNING. FOR SAFETY REASONS AND TO PREVENT FUTURE VIOLATIONS , REPLACED THE BURNT HID BULB ($50+ FROM AMAZON.COM) PERSONALLY (FOLLOWED PROPER PROCEDURES). A WEEK LATER, THAT SAME BULB WENT OUT. MORE EVIDENT INDICATING THE ISSUE IS NOT WITH THE BULB; BUT WITH THE ELECTRICAL SYSTEM AND TOYOTA IS NOT WILLING TO PAID FOR THEIR OWN MISTAKES. SHAME ON TOYOTA!!! *TR

NHTSA ODI #10415147

102,000 miles · Jul 22, 2011
Exterior Lighting

THE MASTER WARNING LIGHT AND ANOTHER LIGHT CAME ON WARNING OF A POSSIBLE MISALIGNMENT OF THE HID HEADLAMPS ON 2005 TOYOTA PRIUS. THIS COULD LEAD TO BLINDING ONCOMING TRAFFIC IF THE LAMPS ARE MISALIGNED. TOYOTA DEALER SERVICE DEPARTMENT CLAIMED THAT EVEN THOUGH IT WAS A COMMON PROBLEM, REPAIRS WOULD COST ~$600 FOR A NEW HEADLIG…

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THE MASTER WARNING LIGHT AND ANOTHER LIGHT CAME ON WARNING OF A POSSIBLE MISALIGNMENT OF THE HID HEADLAMPS ON 2005 TOYOTA PRIUS. THIS COULD LEAD TO BLINDING ONCOMING TRAFFIC IF THE LAMPS ARE MISALIGNED. TOYOTA DEALER SERVICE DEPARTMENT CLAIMED THAT EVEN THOUGH IT WAS A COMMON PROBLEM, REPAIRS WOULD COST ~$600 FOR A NEW HEADLIGHT LEVELING SENSOR (LOAD LEVELING SENSOR) AND INSTALLATION. *TT

NHTSA ODI #10414692

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.

10V036000 · Equipment:other:labels

Feb 3, 2010

SOUTHEAST TOYOTA IS RECALLING CERTAIN MODEL YEAR 2005-2011 PASSENGER VEHICLES FOR FAILING TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 110, "TIRE SELECTION AND RIMS." THESE VEHICLES WERE SOLD WITHOUT THE REQUISITE LOAD CARRYING CAPACITY MODIFICATION LABELS.

Consequence & remedy

Consequence: A DRIVER MAY OVERLOAD A VEHICLE WHICH MAY INCREASE THE RISK OF A CRASH.

Remedy: DEALERS WILL MAIL TO CONSUMERS THE CORRECTED LABEL OR THE CUSTOMER WILL HAVE THE OPTION FOR DEALERS TO INSTALL THE LABEL FREE OF CHARGE. THE SAFETY RECALL BEGAN ON MAY 27, 2010. OWNERS MAY CONTACT SOUTHEAST TOYOTA AT 1-800-301-6859.

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.

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.