2017 Toyota Prius

The catalytic converter heat exchanger failed internally, causing coolant to leak into the exhaust system. Symptoms included white smoke from exhaust and coolant loss with no visible ground leak. This is a documented factory defect per Toyota Technical Service Bulletin T-SB-0135-19 affecting 2016-2019 Prius models. Toyota has denied warranty coverage despite the vehicle was originally bought & spent its entire prior operational life registered in New York, a state covered under Toyota's full 15-year/150,000-mile emissions warranty. Defect was confirmed by an authorized Toyota dealership, in PA. Vehicle had approximately 83,104 miles at time of diagnosis. Manufacturer denied coverage and is forcing the customer (me) to pay a huge amount for this very well known & defective case. MOST IMPORTANTLY ITS dangerous and unsafe for all the cars our there too, since it is very well known that at a certain point this will happen, but despite TOYOTA never sent a RECALL. Due to this, engine light goes on & off, refrigerant is flammable and leaks in the exhaust pipe happens with this specific case, which ultimately could catch on fire, while the vehicle is moving or stalling. Lots of white smoke comes out of the car that directly impact the environmental aspects, and above all, people owning such vehicle, will be running into this issue, which will 100% put the safety of owner and anyone close in proximity to their vehicle at RISK. PLEASE ADD RECALL WITHOUT CAP for ALL SUCH TOYATA PRIUS due to flammable refrigerant leak inside the car engine components, and proven via strong white smoke coming out of exhaust that has the potentially to put the entire car on fire, specifically.

During hot temperatures and after coming to a full stop, the car stalls/hesitates significantly (5-6seconds) when pushing the gas pedal. The car eventually proceeds but the issue reoccurs. It can only be intermittently reproduced and no codes are shown on the car dashboard. Mechanics are unable to identify the source of the issue so it cannot be resolved.

Dear NHTSA, I am seeking assistance and compensation for ongoing warranty and repair issues with my Toyota Prius. Key Incident Timeline: •March 21, 2024: Dashboard message “Grille Shutter Inoperable” •March 25, 2024: Toyota of Glendale visit •Charged $220 for diagnostics •Refused to honor service bulletin •Vehicle mileage: 149,217 Customer Service Interactions: •April 9, 2024: •Contacted Toyota customer service •Confirmed CA emissions coverage to 150,000 miles •Discovered extended warranty unexpectedly canceled Brand Engagement Claim: •April 9, 2024: Filed claim with Toyota’s Brand Engagement line •June 26, 2024: Claim denied, dealership’s decision upheld Repair Challenges: •July 5, 2024: Wondries Toyota diagnostic visit •Charged $200 for diagnostics •Confirmed active service bulletins would have covered repairs Repair Management: •Northeast Mechanic has handled all subsequent repairs due to Toyota’s failures Financial Losses Breakdown: •Initial diagnostic fee (Toyota of Glendale): $220.00 •Diagnostic fee (Wondries Toyota): $200.00 •Car rental (July 6, 2024 - Hertz): $1,356.17 •Car parts: $1,706.55 •Labor on vehicle: $754.22 •Water pump: $167.78 •Head Gasket, Spark Plugs, Engine Water Pump: $2,161.00 •Total financial loss: $6,565.72 I request a comprehensive investigation into these warranty and repair issues, seeking full compensation for the financial burden caused by Toyota’s repeated failures. Sincerely, [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

Dashboard pop up came up saying that the grille shutter is inoperable to visit a dealer. Went online and noticed there were recalls for my Prius year and because emissions is affected I contacted Toyota financial customer service who said to go to a dealer and that they would fix no charge. Went three times to the dealer and they did not want to honor the recall. Charged me $200 to run diagnostics on the vehicle and confirmed that the code that was being recalled matched. They made excuses and in the end did not fix. The pop up appeared March 2024 and since then I now have another pop up appear about the hybrid system overheating due to them not fixing. I went to a local mechanic who said it was the dealers responsibility since there are service bulletins but they do not want to help. The car has stalled out on the freeway almost leaving me to get hit and my fuel has gotten worse.

While filling my Prius with gas, as soon as I started pumping, it spewed gas all over my arms and shirt, as the gas would not go down the pipe into the gas tank. My mechanic explained that gasline exhaust valve was stuck causing the gas to spirt back out the intake opening. This part had to be replaced. Firestone replaced it for a total of $337.08, however, the dealer would have charged more. It was not covered as a defect issue. The experienced mechanic said that he had seen this problem on several Toyotas. This is hazardous and Toyota should repair those that exhibit this problem; also they should change their design so that the exhaust valve does not fail causing gasoline to spill on the person pumping gas and all down the side of the car onto the cement pavement.

When filling gas, a near-empty Prius overflowed almost immediately, splashing fuel over the car, the ground, tires, and my feet! Gas is flammable and not good to get on one's skin. Firestone experienced/certified repairman said that he's repaired many Toyotas with the same problem. No advanced warning was presented. Last time I filled it before this incident it worked fine. Technician said that the air-exhaust that permits air to escape while gas is being delivered to the tank had failed to work properly, causing the fuel to spew back up the gas line and on to the car/ground. He had to order a part from Toyota and replace it. This cost me $337 for part and labor. I believe this is a malfunction that Toyota should cover. This part should not fail as it could start a fire and contaminate the car, ground and put petroleum on people.

THE VEHICLE WAS RUNNING AND STOPPED AT A STOP LIGHT. WHEN ACCELERATING TO PROCEED FROM THE STOP LIGHT THE VEHICLE WOULD BARELY ACCELERATE NO MATTER HOW FAR WE PRESSED THE GAS PEDAL DOWN. THE ENGINE WAS NOT REVVING FASTER IT JUST APPEARED TO STAY IN EV MODE WITH VERY LITTLE ACCELERATION. FINALLY AFTER ABOUT 5-10 SECONDS THE CAR STARTS ACCELERATING. WE ARE VERY CONCERNED THAT IF THIS OCCURS AT A TURN ONTO A BUSY ROAD WE COULD BE IN A POSITION WHERE WE ARE STUCK IN THE MIDDLE OF ONCOMING CROSS TRAFFIC. THIS IS VERY INTERMITTENT, MAYBE ONCE OR TWICE PER SUMMER (USUALLY IN THE HOTTER TIMES OF THE YEAR). WE'VE HAD THE CAR AT THE DEALERSHIP AND BOTH TIMES THEY HAVE SAID THEY FOUND NO PROBLEM. SEARCHING ON THE INTERNET THIS SOUNDS LIKE TSB-0241-17, WHICH I HAVE SHARED WITH THE DEALER BUT BOTH TIMES THEY HAVE INDICATED THEY SEE NO SIGN OFF A PROBLEM.

WHILE I AM SLOWING TO A STOP, A WARNING LIGHT COMES ON INDICATING THAT I AM PRESSING THE BRAKE AND THE ACCELERATOR AT THE SAME TIME. THIS IS NOT POSSIBLE. THE CAR DOES TRY TO MOVE FORWARD BUT PRESSURE ON THE BRAKE OVERCOMES THAT ISSUE. THIS HAS HAPPENED MULTIPLE TIMES (NOT EVERY TIME) BUT FORTUNATELY NO ACCIDENTS HAVE OCCURRED. THIS HAS ALSO NEVER HAPPENED WHEN I AM DRIVING AT HIGHWAY SPEED AND NEED TO BRAKE.

UNABLE TO FILL GAS TANK. VAPOR-CONTAINMENT VALVE ENGAGES DURING REFUELLING, CAUSING FUEL TO SPILL TO GROUND AND UNABLE TO FILL MORE THAT ONE-HALF GALLON OF FUEL. SEE ALSO: HTTPS://PRIUSCHAT.COM/THREADS/INTERESTING-FUEL-ISSUE-2016-THREE-TOURING-OVERFLOWING.173660/ (SEARCH FOR "OVERFLOW" - YOU WILL SEE THAT THIS IS A COMMON PROBLEM)

WHILE DRIVING ON I-75 THERE SEEMS TO BE A SPARK CAUSED FUEL TO LEAK AND BURN BACK TIRE AND THE TIRE ROLLED OFF THE FREEWAY PUTTING ALL THE FIVE PASSENGERS INTO A HAZARDOUS SITUATION ON THE I-75 FREEWAY. WE SMELLED SMELL OF TIRE AND GAS LEAK. FORTUNATELY, WE WERE ABLE TO PULL OFF THE FREEWAY. IT WAS REPORTED TO TOYOTA AND THEIR DEALERS MULTIPLE TIMES. NO ONE EVEN BOTHERED OR CONCERNED ABOUT THE ISSUE OR SAFETY OF PASSENGERS.