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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

What owners actually said

1,051 reports
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

Mileage unknown · Jul 21, 2011
Exterior Lighting

TL* THE CONTACT OWNS A 2005 TOYOTA PRIUS. THE CONTACT STATED THAT THE DRIVERS SIDE HEADLIGHT WOULD INTERMITTENTLY STOP ILLUMINATING. THE CONTACT STATED THAT SHE WOULD HAVE TO TURN THE HEADLIGHTS ON AND OFF SEVERAL TIMES IN ORDER TO KEEP THE LIGHT ILLUMINATED. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER WHERE THE CONTACT WAS IN…

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TL* THE CONTACT OWNS A 2005 TOYOTA PRIUS. THE CONTACT STATED THAT THE DRIVERS SIDE HEADLIGHT WOULD INTERMITTENTLY STOP ILLUMINATING. THE CONTACT STATED THAT SHE WOULD HAVE TO TURN THE HEADLIGHTS ON AND OFF SEVERAL TIMES IN ORDER TO KEEP THE LIGHT ILLUMINATED. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER WHERE THE CONTACT WAS INFORMED THAT THE LIGHTS FIXTURE NEEDED TO BE REPLACED. THE DEALER ALSO STATED THAT THIS WAS A WIDESPREAD ISSUE. THE FAILURE MILEAGE WAS UNKNOWN AND THE CURRENT MILEAGE WAS 96,000.

NHTSA ODI #10413905

74,215 miles · Jul 19, 2011
Service Brakes, ElectricCrash

(1). I SLAMMED ON THE BRAKES, BUT THERE WAS NO POWER BRAKES. THE 2005 PRIUS SLOWED, BUT DID NOT STOP UNTIL IT CRASHED INTO ANOTHER VEHICLE. I WAS GOING APPROXIMATELY 35 MPH, AND I TRAVELED 3 CAR LENGTHS BEFORE COLLIDING WITH THE OTHER VEHICLE. (2). LOSS OF POWER ASSIST HAD PREVIOUSLY OCCURRED WHILE BACKING UP, BUT THIS WAS …

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(1). I SLAMMED ON THE BRAKES, BUT THERE WAS NO POWER BRAKES. THE 2005 PRIUS SLOWED, BUT DID NOT STOP UNTIL IT CRASHED INTO ANOTHER VEHICLE. I WAS GOING APPROXIMATELY 35 MPH, AND I TRAVELED 3 CAR LENGTHS BEFORE COLLIDING WITH THE OTHER VEHICLE. (2). LOSS OF POWER ASSIST HAD PREVIOUSLY OCCURRED WHILE BACKING UP, BUT THIS WAS THE FIRST FAILURE GOING FORWARD. (3). TOTAL LOSS(TOTALED,, $7,000 DAMAGE). THE 2005 PRIUS IS NOW AT AN AUTOMOBILE RECYCLING YARD. )4) I NOTIFIED TOYOTA. BUT I HAD TO CALL THEM BACK SEVERAL TIMES, AND AFTER 15 DAYS, SOMEONE FINALLY ANSWERED, INSTEAD OF ME GETTING THEIR VOICE MAIL. IF THE POWER BRAKES HAD FAILED AT AN INTERSECTION, IT COULD HAVE BEEN A FATAL CRASH. *KB

NHTSA ODI #10413508

106,250 miles · Jul 17, 2011
Exterior Lighting

RIGHT FRONT HEADLIGHT WOULD GO OFF WHILE DRIVING. REQUIRED THAT I SWITCH LIGHTS OFF AND BACK ON TO GET THE LIGHT TO WORK AGAIN. I HAD THE FRONT RIGHT HEADLIGHT REPLACED AND THREE WEEKS LATER THE LEFT FRONT HEADLIGHT FOLLOWED THE SAME SEQUENCE OF EVENTS. I PURCHASED A NEW HEADLIGHT AND HAD TWO DIFFERENT AUTO MECHANICS REPLACE …

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RIGHT FRONT HEADLIGHT WOULD GO OFF WHILE DRIVING. REQUIRED THAT I SWITCH LIGHTS OFF AND BACK ON TO GET THE LIGHT TO WORK AGAIN. I HAD THE FRONT RIGHT HEADLIGHT REPLACED AND THREE WEEKS LATER THE LEFT FRONT HEADLIGHT FOLLOWED THE SAME SEQUENCE OF EVENTS. I PURCHASED A NEW HEADLIGHT AND HAD TWO DIFFERENT AUTO MECHANICS REPLACE IT AND THE LEFT FRONT HEADLIGHT WILL NOT WORK. I AM SCHEDULED TO TAKE THE CAR BACK TO THE LAST MECHANIC NEXT WEEK. VERY UNSAFE TO HAVE THIS HAPPEN WHILE OPERATING THE CAR AT NIGHT AND ANNOYING AND FRUSTRATING THAT THE TOYOTA DEALERSHIP WANTS $300+ TO REPLACE THEIR OBVIOUS MANUFACTURING MALFUNCTION. *TR

NHTSA ODI #10413183

80,000 miles · Jul 15, 2011
Exterior Lighting

TL* THE CONTACT OWNS A 2005 TOYOTA PRIUS. THE CONTACT WAS DRIVING 60 MPH WHEN THE AUTOMATIC HEADLIGHT SENSOR FAILED DUE TO A DESIGN FLAW AND CORROSION. THE CONTACT STATED THAT THE FAILURE COULD POTENTIALLY CAUSE THE HEADLIGHTS TO BLIND THE DRIVERS OF ONCOMING TRAFFIC. THE MANUFACTURE WAS CONTACTED AND OFFERED NO ASSISTANCE. THE…

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TL* THE CONTACT OWNS A 2005 TOYOTA PRIUS. THE CONTACT WAS DRIVING 60 MPH WHEN THE AUTOMATIC HEADLIGHT SENSOR FAILED DUE TO A DESIGN FLAW AND CORROSION. THE CONTACT STATED THAT THE FAILURE COULD POTENTIALLY CAUSE THE HEADLIGHTS TO BLIND THE DRIVERS OF ONCOMING TRAFFIC. THE MANUFACTURE WAS CONTACTED AND OFFERED NO ASSISTANCE. THE FAILURE MILEAGE WAS 80,000.

NHTSA ODI #10412415

176,319 miles · Jul 2, 2011
Exterior Lighting

I HAVE A 2005 (01/01/05) MANUFACTURE DATE PRIUS. I DON'T REMEMBER THE TRIM PACKAGE. I NOTICED THE DRIVERS SIDE HEAD LIGHT WOULD INTERMITTENTLY FAIL CYCLING THE LIGHT OFF AND ON WOULD RESUME OPERATION. ONE WEEK LATER WHILE DRIVING AT NIGHT BOTH HEADLIGHTS COMPLETELY FAILED AGAIN CYCLING THEM OFF AND ON RESUMED OPERATION. I WAS IS…

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I HAVE A 2005 (01/01/05) MANUFACTURE DATE PRIUS. I DON'T REMEMBER THE TRIM PACKAGE. I NOTICED THE DRIVERS SIDE HEAD LIGHT WOULD INTERMITTENTLY FAIL CYCLING THE LIGHT OFF AND ON WOULD RESUME OPERATION. ONE WEEK LATER WHILE DRIVING AT NIGHT BOTH HEADLIGHTS COMPLETELY FAILED AGAIN CYCLING THEM OFF AND ON RESUMED OPERATION. I WAS ISSUED A WARNING WHILE DRIVING HOME FROM WORK BY THE POLICE AND DEMONSTRATED THIS FACT. I HAVE TAKEN THE CAR TO THE DEALER WHO TOLD ME BOTH HEADLIGHTS NEEDED REPLACED AND CHARGED ME 607.25 TO REPLACE. *TR

NHTSA ODI #10410293

111,860 miles · Jun 30, 2011
Electrical SystemFuel System, Gasoline

DRIVING NORTH ON I75 AT APPROXIMATELY 65 MPH. THE GAS GAUGE HAD 3 BARS ILLUMINATED. THE VSC WARNING LIGHT AND THE RED TRIANGLE WITH THE EXCLAMATION POINT CAME ON. I LOST THE ABILITY TO ACCELERATE AND THE CAR SUDDENLY WENT DEAD. LUCKILY I WAS ABLE TO MAKE TO RELATIVE SAFETY ON THE SIDE TO INTERSTATE. THE CAR WAS TOWED TO A DEALER…

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DRIVING NORTH ON I75 AT APPROXIMATELY 65 MPH. THE GAS GAUGE HAD 3 BARS ILLUMINATED. THE VSC WARNING LIGHT AND THE RED TRIANGLE WITH THE EXCLAMATION POINT CAME ON. I LOST THE ABILITY TO ACCELERATE AND THE CAR SUDDENLY WENT DEAD. LUCKILY I WAS ABLE TO MAKE TO RELATIVE SAFETY ON THE SIDE TO INTERSTATE. THE CAR WAS TOWED TO A DEALER WHO SAID THE CAR RAN OUT GAS! THEY ALSO SAID THAT THE "FUEL REGISTER UNIT WAS OPERATING AS DESIGNED." HOW WAS THAT POSSIBLE? THE CHARGE? OVER $1200! ACCORDING TO TOYOTA CORPORATE AND THE DEALERSHIP, REPEATED UNSUCCESSFUL ATTEMPTS TO START THE CAR WILL, BY DESIGN, CAUSE IRREPARABLE DAMAGE TO THE ECU CODE ID BOX WHICH CAN COST $1200 - $1800 TO REPLACE. THIS "DESIGN" IS APPARENTLY IN THE NAME OF ANTI-THEFT PROTECTION. (WHY NOT JUST IMMOBILIZE THE CAR INSTEAD OF PARTIAL SELF-DESTRUCTION?) EVEN GIVEN THE HIGH EXTENT AND DOCUMENTED HISTORY OF GAS GAUGE DISPLAY MALFUNCTIONS AND MANY OTHER RELATED ELECTRICAL PROBLEMS, TOYOTA CORPORATE WOULD OFFER NO FINANCIAL ASSISTANCE, NO REIMBURSEMENT OF ANY PORTION OF THE REPAIR. THIS IS THE SECOND TIME THE CAR HAS LOST ALL POWER IN THE MIDDLE OF HEAVY TRAFFIC. THAT TIME, 08/09/10, THE WATER PUMP FAILED. SUBSEQUENT TO THAT, I RECEIVED A RECALL NOTICE TO REPLACE THE WATER PUMP.

NHTSA ODI #10411085

133,000 miles · Jun 30, 2011
Air BagsCrashInjury

DAUGHTER AND SON-IN-LAW WERE DRIVING MY 2005 TOYOTA PRIUS. A JEEP GRAND CHEROKEE HIT THEM HEAD ON GOING 32-35 MPH. MY S-N-L WAS DRIVING SLOWING DOWN TO A STOP SIGN AND SAW THE JEEP COMING AT THEM ON THEIR SIDE OF THE ROAD SO HE WAS BRAKING HOPING THE JEEP WOULD EITHER STOP OR SWERVE AROUND THEM. THE DRIVER OF THE JEEP DIDN'T …

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DAUGHTER AND SON-IN-LAW WERE DRIVING MY 2005 TOYOTA PRIUS. A JEEP GRAND CHEROKEE HIT THEM HEAD ON GOING 32-35 MPH. MY S-N-L WAS DRIVING SLOWING DOWN TO A STOP SIGN AND SAW THE JEEP COMING AT THEM ON THEIR SIDE OF THE ROAD SO HE WAS BRAKING HOPING THE JEEP WOULD EITHER STOP OR SWERVE AROUND THEM. THE DRIVER OF THE JEEP DIDN'T EVEN BRAKE. HIT THEM HEAD ON MORE ON THE PASSENGER SIDE PUSHING THEM BACK ABOUT 10-15 FT. THE JEEPS AIRBAGS DEPLOYED. THE AIRBAGS ON MY PRIUS DIDN'T. THE DAMAGE TO THE JEEP WAS A SCREWED UP BUMPER AND A BENT LICENSE PLATE. THE DAMAGE TO MY TOYOTA PRIUS WAS TOTALED. ENGINE FLATTENED AND PUSHED IN OVER A FOOT ALMOST UNDER THE DASHBOARD OF CAR. PASSENGER DOOR COULDN'T OPEN UNTIL FIREFIGHTERS PRIED IT OPEN. CALLED TOYOTA, FILED A CLAIM ON DEFECTIVE AIRBAG. MY RESPONSE WAS THEY WEREN'T GOING FAST ENOUGH(ONLY OVER 30 MPH) FOR THE AIRBAGS TO DEPLOY, THEY WEREN'T HIT HARD ENOUGH AND THE DASHBOARD MUST NOT HAVE LOOSENED FROM THE CAR OR ELSE AIRBAGS WOULD HAVE DEPLOYED. MY DAUGHTER TOOK THE BLUNT OF IT. BODY FLEW FORWARD (SHE HAD A SEATBELT ON) HAND HIT DASHBOARD, KNEES HIT GLOVE COMPARTMENT SO HARD THAT IT POPPED OPEN. HOW BAD DOES AN ACCIDENT HAVE TO BE FOR AIRBAGS TO GO OFF. WE PAY FOR SAFETY. THE DRIVER THAT CAUSED THIS WAS DRUNK, WIFE DRUNK AND THEY HAD A 3 YR OLD IN THE CAR AT 10:45 IN THE MORNING. THEY HAD NO INJURIES, THEIR AIR BAGS DEPLOYED. FORGOT TO MENTION DAUGHTERS SISTER-IN-LAW IN SEAT BEHIND HER, WHIPLASH, BRUISES ON LEGS AND BACK IS TWEAKED, BUT THEY WEREN'T HIT HARD ENOUGH. TOYOTA USE TO BE GREAT ON SAFETY AND NOW THEY ARE REALLY BAD AND WON'T FESS UP TO ERRORS. SEARCH TOYOTA AIRBAG DEFECTS AND SEE ALL THE OTHERS THAT HAVE HAD PROBLEMS. SOMEONE WILL HAVE TO DIE PROBABLY HUNDREDS BEFORE SOMETHING IS DONE. *TR

NHTSA ODI #10410154

68,304 miles · Jun 20, 2011
Steering

STEERING FAILURE ON 2005 TOYOTA PRIUS. 2007- SERVICE CAMPAIGN 60C PERFORMED ON THIS PRIUS TO INSPECT/REPLACE STEERING INTERMEDIATE SHAFT AND COMPONENTS. MAY 6, 2011- NOTICED WOBBLE IN STEERING WHEN DRIVING ON SMOOTH HIGHWAY AT 70 MPH. MAY 20, 2011 - TOOK PRIUS IN TO DEALER SERVICE DEPARTMENT FOR: 1] SCHEDULED MAINTENANCE,(OIL/L…

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STEERING FAILURE ON 2005 TOYOTA PRIUS. 2007- SERVICE CAMPAIGN 60C PERFORMED ON THIS PRIUS TO INSPECT/REPLACE STEERING INTERMEDIATE SHAFT AND COMPONENTS. MAY 6, 2011- NOTICED WOBBLE IN STEERING WHEN DRIVING ON SMOOTH HIGHWAY AT 70 MPH. MAY 20, 2011 - TOOK PRIUS IN TO DEALER SERVICE DEPARTMENT FOR: 1] SCHEDULED MAINTENANCE,(OIL/LUBE, ALIGN FRONT SUSPENSION, CLEAN/ADJUST BRAKES, ETC), 2] SNOW TIRE CHANGE-OUT 3] REQUESTED INVESTIGATION OF PROBLEM WITH STEERING WOBBLE. ITEMS 1 AND 2 WERE COMPLETED. ON ITEM 3, DEALER SERVICE DEPARTMENT REPORTED THAT THEY DID NOT FIND A PROBLEM AND STATED IT COULD BE RELATED TO SNOW TIRES OUT OF BALANCE. MAY 26, 2011-COMPLETE STEERING FAILURE OCCURRED WHILE TURNING SLIGHTLY TO THE RIGHT AT ABOUT 15 MPH ON A SMOOTH CITY STREET. THE STEERING WHEEL SPUN UNLIMITED NUMBER OF TIMES TO LEFT AND RIGHT WITH NO EFFECT ON THE WHEELS. THE CAR WAS TOWED TO DEALER. MAY 28, 2011 -DEALER COMPLETED REPAIRS. THE INVOICE SAYS THEY REPLACED: 1 04005-72147 SHAFT KIT, STEERING 1 84306-0E010 CABLE SUB-ASSY SPIR, AND PERFORMED ALIGN FRONT SUSPENSION FOR A TOTAL COST OF $798.22. THE SERVICE ADVISOR REPORTED THE SPLINES AT THE END OF THE INTERMEDIATE SHAFT WERE WORN AND THAT THE TECHNICIAN HAD ONLY SEEN THIS ONCE OR TWICE BEFORE. A COMPLAINT REGARDING SAFETY AND COST HAS BEEN FILED WITH "TOYOTA HELP" (TOYOTA USA). TOYOTA STATED THAT THEY COULD NOT SUPPLY ANY INFORMATION ABOUT INCIDENTS OF THIS TYPE ON OTHER PRIUSES. NEITHER THE SAFETY NOR THE COST COMPLAINT HAS BEEN RESOLVED AT THIS TIME. REPORTED JUNE 20, 2011 *INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6) *TT

NHTSA ODI #10407520

110,000 miles · Jun 7, 2011
Service Brakes, Hydraulic

TL* THE CONTACT OWNS A 2005 TOYOTA PRIUS. THE CONTACT STATED THAT WHILE DRIVING AT VARIOUS SPEEDS HE NOTICED THE ENGINE LIGHT, THE ABS, AND THE BRAKE LIGHT ILLUMINATED. THE VEHICLE THEN STARTED TO MAKE A LOUD CLUNKING NOISE AND THEN WHEN DECELERATING HE NOTICED THAT THE ABS STARTING TO KICK IN WHEN IT SHOULDN'T. THE VEHICLE WAS …

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TL* THE CONTACT OWNS A 2005 TOYOTA PRIUS. THE CONTACT STATED THAT WHILE DRIVING AT VARIOUS SPEEDS HE NOTICED THE ENGINE LIGHT, THE ABS, AND THE BRAKE LIGHT ILLUMINATED. THE VEHICLE THEN STARTED TO MAKE A LOUD CLUNKING NOISE AND THEN WHEN DECELERATING HE NOTICED THAT THE ABS STARTING TO KICK IN WHEN IT SHOULDN'T. THE VEHICLE WAS THEN TAKEN TO A DEALER AND THEY ADVISED HIM THAT THE COMPUTER HAD MALFUNCTIONED ON THE ABS SYSTEM AND THE RIGHT FRONT WHEEL HAD LOCKED UP. THE VEHICLE HAS NOT BEEN REPAIRED. THE MANUFACTURER WAS CONTACTED AND THEY ADVISED HIM THEY WILL ESCALATE THE FAILURE. THE FAILURE AND CURRENT MILEAGES WERE APPROXIMATELY 110,000. THE VIN WAS UNAVAILABLE.

NHTSA ODI #10405440

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.