NHTSA owner reports · September 18, 2026 snapshot.
Service Brakes complaints
30 reportsClear category filter20,000 miles · Jul 7, 2016
Air BagsService BrakesSteeringCrashInjury
TL* THE CONTACT OWNS A 2015 TOYOTA RAV4. WHILE MERGING INTO THE RIGHT LANE, THE VEHICLE INDEPENDENTLY VEERED LEFT AND ACCELERATED WHEN THE BRAKE PEDAL WAS DEPRESSED. THE DRIVER DROVE OFF THE ROAD AND THE VEHICLE ROLLED TWICE DOWN A SHORT INCLINE. BOTH THE DRIVER AND PASSENGER AIR BAGS FAILED TO DEPLOY. A POLICE REPORT WAS FILED.…
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TL* THE CONTACT OWNS A 2015 TOYOTA RAV4. WHILE MERGING INTO THE RIGHT LANE, THE VEHICLE INDEPENDENTLY VEERED LEFT AND ACCELERATED WHEN THE BRAKE PEDAL WAS DEPRESSED. THE DRIVER DROVE OFF THE ROAD AND THE VEHICLE ROLLED TWICE DOWN A SHORT INCLINE. BOTH THE DRIVER AND PASSENGER AIR BAGS FAILED TO DEPLOY. A POLICE REPORT WAS FILED. THE DRIVER AND FRONT PASSENGER SUSTAINED BRUISES AND SCRATCHES TO THEIR ELBOWS. THE REAR PASSENGER SUFFERED A CONCUSSION, WHICH REQUIRED MEDICAL ATTENTION. THE VEHICLE WAS DESTROYED AND TOWED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS 20,000.
NHTSA ODI #10883451
14,000 miles · Jun 23, 2016
Service BrakesVehicle Speed ControlCrash
WHILE PULLING UP TO A GAS PUMP THE CAR SUDDENLY ACCELERATED. IT WENT FROM ZERO TO 40 MILES PER HOUR. I WAS IN THE PASSENGER SEAT AND MY HUSBAND WAS DRIVING. HE PUMPED THE BRAKES BUT CAR MADE A LOUD REVVING NOISE AND WOULD NOT STOP. MY HUSBAND WAS ABLE TO AVOID HITTING A TRUCK, BUT THE CAR WENT OVER A CONCRETE MEDIANO AND ONLY CA…
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WHILE PULLING UP TO A GAS PUMP THE CAR SUDDENLY ACCELERATED. IT WENT FROM ZERO TO 40 MILES PER HOUR. I WAS IN THE PASSENGER SEAT AND MY HUSBAND WAS DRIVING. HE PUMPED THE BRAKES BUT CAR MADE A LOUD REVVING NOISE AND WOULD NOT STOP. MY HUSBAND WAS ABLE TO AVOID HITTING A TRUCK, BUT THE CAR WENT OVER A CONCRETE MEDIANO AND ONLY CAME TO A STOP WHEN THE EMERGENCY BRAKE WAS PULLED. THE CAR WAS FILLED WITH AIRBAG SMOKE EVEN THOUGH THE AIRBAGS DID NOT DEPLOY. A WITNESS SAID THAT HE COULD TELL IT WAS A MECHANICAL ISSUE BECAUSE OF THE LOUD REVVING NOISE THE CAR WAS MAKING. TOYOTA HAS NOT BEEN ABLE TO TELL US WHAT HAPPENED. THEY DID NOT FIND A PROBLEM WITH BRAKES OR ACCELERATOR. THE CAR HIT THE MEDIAN SO HARD THAT THE FRAME HAS BEEN BENT. EVEN THOUGH WE HAVE BEEN LOYAL TOYOTA CUSTOMER FOR OVER 20 YEARS, MY HOPE IS THAT THEY TOTAL THE CAR SO THAT I DON'T EVER HAVE TO DRIVE IT AGAIN. OUR TOYOTA CASE # IS1604122141. I KNOW THAT OTHER PEOPLE HAVE HAD SIMILAR EXPERIENCES-THERE IS NO DOUBT IN MY MIND THAT THERE IS A SERIOUS PROBLEM WITH THAT CAR.
NHTSA ODI #10876294
18,000 miles · May 11, 2016
Service BrakesCrash
INTERMITTENT BRAKE FAILURE. TWO INSTANCES OF BRAKES FAILING TO ENGAGE WHEN PRESSURE APPLIED. FIRST INSTANCE CAUSED CAR TO CRASH INTO CONCRETE MEDIAN; NO DAMAGE TO VEHICLE OR STRUCTURE AND INCIDENT NOT REPORTED. SECOND BRAKE FAILURE APRIL 14, 2016 AS CAR WAS DESCENDING PARKING LOT DRIVEWAY (DOWNHILL SLOPE) AND DRIVER APPLIED BRAK…
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INTERMITTENT BRAKE FAILURE. TWO INSTANCES OF BRAKES FAILING TO ENGAGE WHEN PRESSURE APPLIED. FIRST INSTANCE CAUSED CAR TO CRASH INTO CONCRETE MEDIAN; NO DAMAGE TO VEHICLE OR STRUCTURE AND INCIDENT NOT REPORTED. SECOND BRAKE FAILURE APRIL 14, 2016 AS CAR WAS DESCENDING PARKING LOT DRIVEWAY (DOWNHILL SLOPE) AND DRIVER APPLIED BRAKES. BRAKES FAILED TO ENGAGE. AS DRIVER WAS ATTEMPTING TO ENGAGE THE EMERGENCY BRAKE THE CAR CAREENED OVER A COMMENT CURB, THROUGH A CHAIN LINK FENCE AND INTO A GAS MAIN AND APARTMENT BUILDING WALL. DRIVER SUSTAINED SOME INJURY TO NECK AND BACK DUE TO FORCE OF IMPACT. AIRBAG DID NOT DEPLOY. CAR WAS TOWED OUT OF ACCIDENT BACK ON TO THE ACCESS ROAD. POLICE OFFICERS IN TAKOMA PARK, MD THEN TESTED CAR. ACCIDENT REPORT DESCRIBES "IMPACT AND DAMAGE" AS "DISABLING", HOWEVER OWNER WAS TOLD TO DRIVE THE CAR HOME. DRIVER IS NOT FLUENT IN ENGLISH AND DUE TO TRANSLATION ERRORS THE POLICE REPORT DOES NOT ACCURATELY REFLECT THE ACTUAL CAUSE OF ACCIDENT. CAR IS NOW AT DARCARS TOYOTA IN ROCKVILLE WITH AT LEAST $12,000 IN REPAIRS PENDING. OWNER HAS AUTO INSURANCE AND CAR WILL BE REPAIRED OR TOTALED OUT. HOWEVER, OWNER IS (UNDERSTANDABLY) TERRIFIED TO DRIVE THE RAV4 AGAIN FOR FEAR THAT THE BRAKES WILL FAIL A THIRD TIME - WITH POSSIBLLY CATASTROPHIC CONSEQUENCES TO DRIVER AND OTHERS. OWNER SPEAKS LIMITED ENGLISH AND IS A FRIEND OF THE FAMILY. I AM CONCERNED FOR NOT ONLY HER SAFELY, BUT THE SAFELY OF OTHERS EITHER FROM AN ACCIDENT THAT COULD BE CAUSED BY THIS CAR OR A SERIOUS MALFUNCTION THAT AFFECTS A GREATER NUMBER OF RAV4'S ON THE ROAD. I BELIEVE THIS ISSUE SHOULD BE VERY SERIOUSLY INVESTIGATED BEFORE PLACING THE CAR ON THE ROAD AGAIN.
NHTSA ODI #10864472
6,000 miles · May 10, 2016
Air BagsService BrakesCrashInjury
TL* THE CONTACT OWNS A 2015 TOYOTA RAV4. THE CONTACT STATED THAT WHILE DRIVING AT 10 MPH DOWN AN INCLINE, THE BRAKE PEDAL WAS DEPRESSED BUT THE VEHICLE FAILED TO STOP. AS A RESULT OF THE FAILURE, THE CONTACT CRASHED INTO A WALL AND THE AIR BAGS FAILED TO DEPLOY. THE CONTACT MENTIONED THAT THE FAILURE HAD RECURRED TWICE. A POLICE…
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TL* THE CONTACT OWNS A 2015 TOYOTA RAV4. THE CONTACT STATED THAT WHILE DRIVING AT 10 MPH DOWN AN INCLINE, THE BRAKE PEDAL WAS DEPRESSED BUT THE VEHICLE FAILED TO STOP. AS A RESULT OF THE FAILURE, THE CONTACT CRASHED INTO A WALL AND THE AIR BAGS FAILED TO DEPLOY. THE CONTACT MENTIONED THAT THE FAILURE HAD RECURRED TWICE. A POLICE REPORT WAS FILED. THE DRIVER SUSTAINED BACK AND NECK INJURIES THAT REQUIRED MEDICAL ASSISTANCE. THE VEHICLE WAS TAKEN TO THE DEALER. THE TECHNICIAN WAS UNABLE TO DIAGNOSE THE FAILURE. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS 6,000.
NHTSA ODI #10864263
140,000 miles · Dec 23, 2015
Service BrakesSteeringCrashInjury
TL* THE CONTACT OWNS A 2015 TOYOTA RAV4. THE CONTACT STATED THAT WHILE DRIVING AT 30 MPH, A VEHICLE STOPPED IN FRONT OF THE CONTACTS VEHICLE. THE BRAKE PEDAL WAS DEPRESSED AND FAILED TO RESPOND AS THE STEERING WHEEL SEIZED. AS A RESULT. THE CONTACT CRASHED INTO A TREE. THE AIR BAGS DEPLOY, RELEASING A CHEMICAL SUBSTANCE. THE CON…
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TL* THE CONTACT OWNS A 2015 TOYOTA RAV4. THE CONTACT STATED THAT WHILE DRIVING AT 30 MPH, A VEHICLE STOPPED IN FRONT OF THE CONTACTS VEHICLE. THE BRAKE PEDAL WAS DEPRESSED AND FAILED TO RESPOND AS THE STEERING WHEEL SEIZED. AS A RESULT. THE CONTACT CRASHED INTO A TREE. THE AIR BAGS DEPLOY, RELEASING A CHEMICAL SUBSTANCE. THE CONTACT SUSTAINED ARM, LEGS AND WHIPLASH INJURIES THAT REQUIRED MEDICAL ATTENTION. A POLICE REPORT WAS FILED. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE AND THE VIN WAS NOT INCLUDED IN NHTSA CAMPAIGN NUMBER: 15V144000 (STEERING). THE APPROXIMATE FAILURE MILEAGE WAS 140,000. THE VIN WAS NOT AVAILABLE. UPDATED 04/07/16*LJ...UPDATED 12/06/16 *BF UPDATED 03/09/17.*JB
NHTSA ODI #10811893
1,500 miles · Oct 22, 2015
Service BrakesCrashInjury
BRAKES DID NOT RESPOND WHILE DRIVING AND AN ACCIDENT OCCURRED.
NHTSA ODI #10785270
4,000 miles · Aug 18, 2015
Service Brakes
TL* THE CONTACT OWNS A 2015 TOYOTA RAV4. WHILE DRIVING AT APPROXIMATELY 25 MPH, THE CRUISE CONTROL WARNING LIGHT ILLUMINATED AND FLICKERED. IN ADDITION, THERE WAS AN ABNORMAL NOISE COMING FROM THE VEHICLE. THE CONTACT STATED THAT THE VEHICLE WAS TAKEN TO A DEALER WHERE IT WAS DIAGNOSED THAT THE ANTI-LOCK BRAKE SYSTEM FAILED. THE…
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TL* THE CONTACT OWNS A 2015 TOYOTA RAV4. WHILE DRIVING AT APPROXIMATELY 25 MPH, THE CRUISE CONTROL WARNING LIGHT ILLUMINATED AND FLICKERED. IN ADDITION, THERE WAS AN ABNORMAL NOISE COMING FROM THE VEHICLE. THE CONTACT STATED THAT THE VEHICLE WAS TAKEN TO A DEALER WHERE IT WAS DIAGNOSED THAT THE ANTI-LOCK BRAKE SYSTEM FAILED. THE BRAKES, PADS, AND ROTORS WERE REPLACED. IN ADDITION, BOTH FRONT TIRES WERE REPLACED, BUT THE FAILURE RECURRED. THE APPROXIMATE FAILURE MILEAGE WAS 4,000.
NHTSA ODI #10749407
70,010 miles · Aug 17, 2015
EngineService Brakes
TL* THE CONTACT OWNS A 2015 TOYOTA RAV4. WHILE DRIVING 5 MPH, THE BRAKE PEDAL WAS SLIGHTLY DEPRESSED AND THE ENGINE REVVED. THE BRAKES FAILED TO RESPOND AND THE EMERGENCY BRAKE WAS ENGAGED IN ORDER TO STOP THE VEHICLE. THE VEHICLE WAS TAKEN THE DEALER, BUT WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILU…
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TL* THE CONTACT OWNS A 2015 TOYOTA RAV4. WHILE DRIVING 5 MPH, THE BRAKE PEDAL WAS SLIGHTLY DEPRESSED AND THE ENGINE REVVED. THE BRAKES FAILED TO RESPOND AND THE EMERGENCY BRAKE WAS ENGAGED IN ORDER TO STOP THE VEHICLE. THE VEHICLE WAS TAKEN THE DEALER, BUT WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS 70,010.
NHTSA ODI #10749152
10,000 miles · Jul 29, 2015
Service BrakesSteeringWheels
I PURCHASE THE RAV4 IN OCTOBER 2015, AND THREE MONTHS AFTER THE PURCHASE I STARTED TO EXPERIENCE A CRUNCHING SOUND COMING FROM MY BRAKES AND A FLUCTUATION ISSUE WHERE THE BRAKES DO NOT ALWAYS CATCH CAUSING A SAFETY CONCERN. THE DEALER AND TOYOTA ARE REFUSING ON TWO OCCASIONS TO ACKNOWLEDGE THE ISSUE. I TOOK THE CAR IN TO THE TOY…
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I PURCHASE THE RAV4 IN OCTOBER 2015, AND THREE MONTHS AFTER THE PURCHASE I STARTED TO EXPERIENCE A CRUNCHING SOUND COMING FROM MY BRAKES AND A FLUCTUATION ISSUE WHERE THE BRAKES DO NOT ALWAYS CATCH CAUSING A SAFETY CONCERN. THE DEALER AND TOYOTA ARE REFUSING ON TWO OCCASIONS TO ACKNOWLEDGE THE ISSUE. I TOOK THE CAR IN TO THE TOYOTA DEALER AGAIN ON 7/28/2015 IN HOPES THAT THEY WILL FINALLY FIX THE ISSUE. THE DEALER WILL NOT DOCUMENT THE ISSUE!
NHTSA ODI #10744552
4,500 miles · Jul 27, 2015
Service BrakesInjury
I USED TO HAVE A 2004 TOYOTA HIGHLANDER LIMITED AND HAVE NEVER HAD THIS PROBLEM WITH THIS RAV 4 LIMITED. SOMETIMES WHEN I PARK, I FORGET TO PUT THE VEHICLE IN PARK (I NEVER HAD THIS HAPPEN WITH MY HIGHLANDER) AND THEN TAKE MY FOOT OFF THE BRAKE. MY HIGHLANDER DID NOT DO THIS. TODAY MY CAR STARTED ROLLING BACKWARDS. I FELL D…
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I USED TO HAVE A 2004 TOYOTA HIGHLANDER LIMITED AND HAVE NEVER HAD THIS PROBLEM WITH THIS RAV 4 LIMITED. SOMETIMES WHEN I PARK, I FORGET TO PUT THE VEHICLE IN PARK (I NEVER HAD THIS HAPPEN WITH MY HIGHLANDER) AND THEN TAKE MY FOOT OFF THE BRAKE. MY HIGHLANDER DID NOT DO THIS. TODAY MY CAR STARTED ROLLING BACKWARDS. I FELL DOWN AND MY ELBOW AND ARM IS REALLY SCRAPPED UP AS I WAS TRYING TO STOP THE CAR WITH MY BODY AND THEN I WAS ALMOST RUN OVER AS I FELL ON THE GROUND. I COULD HAVE HIT A CHILD OR RUN OVER A CHILD. I DON'T KNOW IF THIS IS SOME TYPE OF PROBLEM WITH MY CAR OR IF THERE IS A SETTING I COULD USE TO PREVENT THIS. I DON'T WANT TO BE RUN OVER BY MY CAR OR HAVE ANYONE RUN OVER.
NHTSA ODI #10743781
Official recalls
4Nov 1, 2023
Toyota Motor Engineering & Manufacturing (Toyota) is recalling certain 2013-2018 RAV4 vehicles. Certain replacement 12-volt batteries may not fit properly in the battery tray, allowing the battery to move and contact the hold-down bracket, possibly causing a short circuit.
Consequence & remedy
Consequence: A battery short circuit increases the risk of a fire.
Remedy: Dealers will replace the battery clamp sub-assembly, battery tray, and positive terminal cover, free of charge. Owner letters were mailed December 27, 2024, to 2013-2014 RAV4 owners. Additional owner notification letters will be mailed in phases, phase 2 will begin on May 14, 2025, and phase 3 in late July 2025. Owners may contact Toyota's customer service at 1-800-331-4331. Toyota's numbers for this recall are 23TB13 and 23TA13.
Mar 13, 2015
Toyota Motor Engineering & Manufacturing (Toyota) is recalling certain model year 2015 Camry, Camry Hybrid, Highlander, and Highlander Hybrid, and 2014-2015 Rav4 vehicles. A component of the electric power steering (EPS) electronic control unit (ECU) may have been damaged during the manufacturing process. Over time, this damage may result in failure of the electric power steering system.
Consequence & remedy
Consequence: An unexpected loss of power steering increases the risk of a crash.
Remedy: Toyota will notify owners, and dealers will inspect the serial number of the EPS ECU or steering column assembly. If the number is within the affected range, the EPS ECU will be replaced, free of charge. The recall began on May 7, 2015. Owners may contact Toyota customer service at 1-800-331-4331.
Jan 16, 2015
Southeast Toyota Distributors, LLC (SET) is recalling certain model year 2013-2015 Toyota Rav4 vehicles manufactured June 1, 2013, to December 29, 2014, and equipped with an accessory trailer light module. The software within the module may incorrectly detect an electrical short and preventively turn off the electrical current and the trailer lights.
Consequence & remedy
Consequence: If the system incorrectly detects an electrical short and turns off the trailer lights while the trailer is being towed at night, there is an increased risk of a crash.
Remedy: SET will notify owners, and dealers will replace the trailer light module with a new unit with corrected software, free of charge. The recall began on March 17, 2015. Owners may contact SET customer service at 1-866-405-4226. SET's number for this recall is SET-15A.
Additional source detail variants (2)
Trailer Hitches
Southeast Toyota Distributors, LLC (SET) is recalling certain model year 2013-2015 Toyota Rav4 vehicles manufactured June 1, 2013, to December 29, 2014, and equipped with an accessory trailer light module. The software within the module may incorrectly detect an electrical short and preventively turn off the electrical current and the trailer lights.
Consequence: If the system incorrectly detects an electrical short and turns off the trailer lights while the trailer is being towed at night, there is an increased risk of a crash.
Remedy: SET will notify owners, and dealers will replace the trailer light module with a new unit with corrected software, free of charge. The recall began on March 17, 2015. Owners may contact SET customer service at 1-866-405-4226. SET's number for this recall is SET-15A.
Exterior Lighting
Southeast Toyota Distributors, LLC (SET) is recalling certain model year 2013-2015 Toyota Rav4 vehicles manufactured June 1, 2013, to December 29, 2014, and equipped with an accessory trailer light module. The software within the module may incorrectly detect an electrical short and preventively turn off the electrical current and the trailer lights.
Consequence: If the system incorrectly detects an electrical short and turns off the trailer lights while the trailer is being towed at night, there is an increased risk of a crash.
Remedy: SET will notify owners, and dealers will replace the trailer light module with a new unit with corrected software, free of charge. The recall began on March 17, 2015. Owners may contact SET customer service at 1-866-405-4226. SET's number for this recall is SET-15A.
Dec 30, 2014
Southeast Toyota Distributors, LLC (SET) is recalling certain model year 2014-2015 Toyota 4Runner, Tacoma, FJ Cruiser, Land Cruiser, RAV4, Scion FRS, and XB vehicles. The affected vehicles may have accessories installed by SET, such as running boards or other items, that were incorrectly installed. The accessory attaching fasteners were not tightened with the proper torque, possibly causing the accessory to detach from the vehicle.
Consequence & remedy
Consequence: Accessories that detach from a vehicle may result in a vehicle crash and/or personal injury.
Remedy: SET will notify owners, and dealers will inspect and tighten the affected bolts, free of charge. The recall began February 23, 2015. Owners may contact SET customer service at 1-866-405-4226. SET's number for this recall is SET-14B.
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
1PE21005 · Battery Hold Down Bracket Thermal Events
Opened Feb 25, 2021 · Closed Aug 12, 2024
Status: closed (inferred from source dates) · Electrical SYSTEM:12V/24V/48V Battery
The Office of Defects Investigation (ODI) opened a Preliminary Evaluation (PE) to understand the contributing factors and frequency of vehicle fires originating from the battery region of the engine compartment in Model Year (MY) 2013-2018 Toyota RAV4 vehicles on 25 February 2021. At the time of opening, ODI attributed eleven allegations and additional EWR events to this PE. PE21005 focused on replacement batteries installed in the subject vehicles. No reported fire event identified in PE21005 involved the originally supplied 12V battery. The reported fires took place in vehicles known to contain aftermarket batteries or whose age exceeded the expected life of the original equipment battery. ODI identified battery dimensioning as it relates to the battery retention system (hold down bracket, radiator support bolt, J-hook, and battery tray) as the main factor set in the contact between the battery hold down bracket contacting the positive terminal of the 12V battery. The subject vehicles carried over the same battery tray and retention system from the prior generation (MY2006 – MY2012) of RAV4 vehicles. However, the subject vehicles were equipped with a dimensionally smaller battery (Group 35) than the prior generation (Group 24F). The smaller- length measurement in the Group 35 battery size in a battery tray originally designed to fit a Group 24F battery contributed to increased potential for battery movement which was exacerbated by the diversity in aftermarket battery configuration and irregularities intrinsic to battery replacement procedures. Battery movement coupled with the proximity of the B+ terminal on the battery and the grounded electrically conductive hold down bracket set the stage for a short to ground leading to an engine stall (if in operation) followed by a vehicle fire. This investigation was not able to classify the installation status, battery size, or cause of every allegation due to the fire event causing damage to the area, inaccessible vehicle, modification to the battery retention system after the event, and/or inconclusive photographic evidence. Toyota's investigation of the issue identified aftermarket battery catalogs that listed an improper battery replacement size (Group 26R) that would nevertheless fit into the subject vehicles whose battery retention system is incapable of reliably restraining a Group 26R battery. On 18 November 2021, Toyota initiated a consumer advisory campaign (21TG01) to the subject vehicle owners, notifying them of the correct size battery and offering a free inspection of the battery and retention hardware, a caution label to affix to the hold down bracket, and a discounted replacement 12V battery. This investigation with Toyota established three broad categories to characterize the battery retention system state of a given vehicle: "correct", "minor mis-installation", and "major mis-installation". - The "correct" terminology references the front bolt, bracket, and J-hook installed in a position not in contact with the positive battery terminal and the front bolt torqued to 17 Nm and the J-hook engaged with the tray hole and torqued to 4.9 Nm. - A "minor mis-installation" would describe the three retention components installed in the prescribed location, however not to the correct torque values. - The "major mis-installation" condition would constitute a retention component missing or disconnected from the system. Toyota's own testing used five exemplar batteries installed on a subject vehicle in each battery categorization resulted in: - Contact between the B+ terminal and hold down bracket in "major mis-installations" - Movement of the battery in "minor mis-installations" - No observable motion in "correct" installations. ODI conducted its own evaluation of the Toyota- specified replacement battery and 5 aftermarket Group 35 batteries. The six batteries tested conformed to the Group 35 Battery Council International (BCI) standard on overall dimensional tolerance and terminal location. That standard does not define the edge shape or material of battery casing. Physical interaction between the hold down bracket and the battery case and the friction between the casing material and the battery tray resulted in a large variability in movement forces required to incite movement when the battery was installed in the "correct" condition. Resulting in movement at an induced lateral load between 0.6 G and 1.91 G equivalent force across each battery. This force is higher than a typical vehicle could exert in a steady state turn and would only experience loads through brief shock or impulses. Multiple shock or impulse loads across time would contribute to a delay between the replacement battery installation and the fire event. Likelihood of a fire event increases as the installation method degraded from the "correct", to "minor mis-installation", and then to "major mis-installation". Protruding vent caps atop some of the batteries tested aided in restricting battery movement relative to the hold down. An absence of vent caps permitted additional movement. Following several discussions and vehicle inspections with ODI during this investigation, on 01 November 2023, Toyota filed a safety recall (NHTSA 23V-734) of 1,853,568 MY 2013 through MY 2018 Toyota RAV4 vehicles to reduce the risk of a vehicle fire with redesigned battery retention components. To review the ODI reports cited in the Closing Resume ODI Report Identification Number document, go to NHTSA.gov.
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