THE CAR WAS BEING DRIVEN IN PHILADELPHIA AT A LOW SPEED WHEN THE ENGINE CAUGHT FIRE. THE FIRE QUICKLY WAS OUT OF CONTROL AND DESTROYED MOST OF THE CAR, INCLUDING THE ENGINE, DASHBOARD, FRONT SEATS, WINDSHIELD, WINDOWS, FRONT TIRES WHICH EXPLODED, AND AIRBAGS.
2015 Toyota RAV4
Owner reports · Recalls · Investigations
Similar to other model years
Owner complaints for the 2015 Toyota RAV4 do not stand out strongly from the model-year median of 258.5.
About this comparison →How this year compares
Owner complaints by model year
Compare all RAV4 years →Counts vary with age, sales and reporting. They are not failure rates.
What owners reported most
All reported categories
Tap a category to read its complaints. One report may name several components.
When problems were reported
Mileage at the reported incident
170 reports with mileage · 133 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.
- Electrical System. Review the 84 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Steering. Review the 45 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Engine. Review the 37 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
NHTSA owner reports · September 18, 2026 snapshot.
What owners actually said
303 reportsTL* THE CONTACT OWNS A 2015 TOYOTA RAV4. WHILE THE CONTACT'S FOOT WAS DEPERESSING THE BRAKE PEDAL AND THE VEHICLE WAS IN DRIVE, IT ACCELERATED INDEPENDENTLY. THE VEHICLE WAS TAKEN TO THE DEALER TO BE DIAGNOSED. THE VEHICLE WAS DIAGNOSED, BUT THE CONTACT WAS NOT GIVEN AN EXPLANATION FOR THE FAILURE. THE CONTACT STATED THAT THE FA…
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TL* THE CONTACT OWNS A 2015 TOYOTA RAV4. WHILE THE CONTACT'S FOOT WAS DEPERESSING THE BRAKE PEDAL AND THE VEHICLE WAS IN DRIVE, IT ACCELERATED INDEPENDENTLY. THE VEHICLE WAS TAKEN TO THE DEALER TO BE DIAGNOSED. THE VEHICLE WAS DIAGNOSED, BUT THE CONTACT WAS NOT GIVEN AN EXPLANATION FOR THE FAILURE. THE CONTACT STATED THAT THE FAILURE OCCURRED ONLY ONCE. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 4,000. THE VIN WAS UNAVAILABLE.
TL* THE CONTACT OWNS A 2015 TOYOTA RAV4. WHILE DRIVING 20 MPH, THE ACCELERATOR PEDAL WAS DEPRESSED AND THE VEHICLE FAILED TO RESPOND. THE VEHICLE WAS TAKEN TO THE DEALER TO BE DIAGNOSED. THE CONTACT STATED THAT THE DEALER WAS UNABLE TO DUPLICATE THE FAILURE. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED OF THE …
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TL* THE CONTACT OWNS A 2015 TOYOTA RAV4. WHILE DRIVING 20 MPH, THE ACCELERATOR PEDAL WAS DEPRESSED AND THE VEHICLE FAILED TO RESPOND. THE VEHICLE WAS TAKEN TO THE DEALER TO BE DIAGNOSED. THE CONTACT STATED THAT THE DEALER WAS UNABLE TO DUPLICATE THE FAILURE. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 15,000.
I HAD A VERY DANGEROUS EXPERIENCE WITH A 2015 TOYOTARV4 XLE. I WAS GOING UP AN EXIT RAMP SLOWLY WITH THE TRAFFIC GOING AND STOPPING WHEN ALL OF A SUDDEN MY RIGHT FOOT WAS STUCK BETWEEN THE ACCELERATOR AND THE BRAKE PEDAL. I COULD NOT RETRACT MY FOOT TO BRAKE, CAUSING THE VEHICLE TO CONTINUING GOING FORWARD. I BELIEVE THAT THERE …
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I HAD A VERY DANGEROUS EXPERIENCE WITH A 2015 TOYOTARV4 XLE. I WAS GOING UP AN EXIT RAMP SLOWLY WITH THE TRAFFIC GOING AND STOPPING WHEN ALL OF A SUDDEN MY RIGHT FOOT WAS STUCK BETWEEN THE ACCELERATOR AND THE BRAKE PEDAL. I COULD NOT RETRACT MY FOOT TO BRAKE, CAUSING THE VEHICLE TO CONTINUING GOING FORWARD. I BELIEVE THAT THERE IS A SERIOUS PROBLEM WITH THIS VEHICLE BRAKING/ACCELERATION DUE TO THE SHORT SPACE BETWEEN AND OR THE HEIGHT OF THE BRAKE PEDAL TO THE ACCELERATOR PEDAL. THIS ISSUE HAS BEEN DOCUMENTED BY MANY OTHER DRIVERS THAT I HAVE READ ABOUT AND I AM SURE THIS NOT NEW TO THE TOYOTA COMPANY. I HAVE BEEN IN TOUCH WITH THE TOYOTA CUSTOMER EXPERIENCE CENTER AND HAVE FILED A CASE NUMBER.
TL* THE CONTACT OWNS A 2015 TOYOTA RAV4. WHILE ENTERING AN ON-RAMP, THE CONTACT'S VEHICLE UNEXPECTEDLY ACCELERATED AND CRASHED INTO ANOTHER VEHICLE. THE AIR BAGS DID NOT DEPLOY. A POLICE REPORT WAS FILED. THERE WERE NO INJURIES SUSTAINED. THE CONTACT DROVE THE VEHICLE TO A DEALER WHERE IT WAS DIAGNOSED THAT THE DRIVER SIDE FENDE…
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TL* THE CONTACT OWNS A 2015 TOYOTA RAV4. WHILE ENTERING AN ON-RAMP, THE CONTACT'S VEHICLE UNEXPECTEDLY ACCELERATED AND CRASHED INTO ANOTHER VEHICLE. THE AIR BAGS DID NOT DEPLOY. A POLICE REPORT WAS FILED. THERE WERE NO INJURIES SUSTAINED. THE CONTACT DROVE THE VEHICLE TO A DEALER WHERE IT WAS DIAGNOSED THAT THE DRIVER SIDE FENDER AND PANEL NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE VIN AND FAILURE MILEAGE WERE UNKNOWN.
I HAVE HAD THIS CAR FOR ROUGHLY 10 MONTHS. IT WAS BOUGHT BRAND NEW. I HAVE HAD TO REPLACE TWO WINDSHIELDS IN THAT TIME. ONE WAS CRACKED IN EARLY OCTOBER 2015 AND REPLACED ON NOVEMBER 7, 2015(LENGTHY DUE TO REPLACEMENT UNAVAILABILITY). THE OTHER HAPPENED ON DECEMBER 23,2015 AND REPLACED ON DECEMBER 26,2015 BOTH CRACKS WERE DUE TO…
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I HAVE HAD THIS CAR FOR ROUGHLY 10 MONTHS. IT WAS BOUGHT BRAND NEW. I HAVE HAD TO REPLACE TWO WINDSHIELDS IN THAT TIME. ONE WAS CRACKED IN EARLY OCTOBER 2015 AND REPLACED ON NOVEMBER 7, 2015(LENGTHY DUE TO REPLACEMENT UNAVAILABILITY). THE OTHER HAPPENED ON DECEMBER 23,2015 AND REPLACED ON DECEMBER 26,2015 BOTH CRACKS WERE DUE TO (WHAT I CONSIDER) RELATIVELY SMALL STONE CHIPS THAT HAPPENED WHILE DRIVING ON INTERSTATE 90 NEAR NORTH EAST, PA. I HAVE OWNED IN EXCESS OF 15 VEHICLES IN MY 44 YEARS OF DRIVING. I HAVE NEVER HAD TO REPLACE A WINDSHIELD IN ANY OF THE OTHERS (YES SOME REPAIRS WERE DONE). I AM QUESTIONING IF THE WINDSHIELDS IN THESE CARS ARE BEING MANUFACTURED TO THE SAME SPECIFICATIONS AS IN THE PAST AND IF NOT DO THEY STILL MEET THE CURRENT SAFETY STANDARDS.
THE CAR SIGNIFICANTLY ACCELERATES WHEN BACKING OUT OF THE GARAGE. WHEN STOPPED FOR A RED LIGHT IT IS EAGER TO GO IF THE BRAKES ARE NOT DEPRESSED VERY FIRMLY AND BETWEEN 20 AND 40 MILES PER HOUR IT SHIFTS INTO A HIGHER GEAR WITH UNINTENDED ACCELERATION. IT HAS ALSO DONE THIS WHEN ONCE GOING UP A HILL AT 39 MILES PER HOUR. IT F…
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THE CAR SIGNIFICANTLY ACCELERATES WHEN BACKING OUT OF THE GARAGE. WHEN STOPPED FOR A RED LIGHT IT IS EAGER TO GO IF THE BRAKES ARE NOT DEPRESSED VERY FIRMLY AND BETWEEN 20 AND 40 MILES PER HOUR IT SHIFTS INTO A HIGHER GEAR WITH UNINTENDED ACCELERATION. IT HAS ALSO DONE THIS WHEN ONCE GOING UP A HILL AT 39 MILES PER HOUR. IT FEELS DANGEROUS TO ME WHEN I AM APPROACHING A STOP SIGN AND IT CHOOSES TO ACCELERATES UNLESS I AM BRAKING LONG BEFORE THE SIGN. THE CAN WAS EXAMINED BY THE DEAQLERSHIP 2 TIMES AND "NOTHING WAS FOUND". I THEN CONTACTED SOMEONE IN TOYOTA'S COLORADO ADMINISTRATIVE OFFICE. THIS PERSON TOOK A COMPUTER APPARATUS ATTACHED IT TO MY CAR, WE TEST DROVE IT AROUND AND THEY DETERMINED IT DOES AUTOMATICALLY SHIFT INTO 5TH GEAR DURING THESE ACCELERATION TIMES. THE CAR FEELS UNSAFE AND WILL SOONER OR LATER BE THE CAUSE OF AN ACCIDENT.
THE ROOF RACK THAT CAME WITH THE RAV4 STATES THAT EACH STRUT CAN HOLD 100LBS, BUT IN THE MANUAL IT STATES THAT IT IS 100 LBS TOTAL. I PURCHASED SOME LUMBER AND MY ROOF RACK FAILED ON THE RETURN TRIP HOME. I BELIEVE IT HAPPENED WHEN I WAS DRIVING ON THE HIGHWAY. ONE SIDE OF EACH STRUT BROKE AND DENTED THE ROOF OF MY CAR. IF THE O…
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THE ROOF RACK THAT CAME WITH THE RAV4 STATES THAT EACH STRUT CAN HOLD 100LBS, BUT IN THE MANUAL IT STATES THAT IT IS 100 LBS TOTAL. I PURCHASED SOME LUMBER AND MY ROOF RACK FAILED ON THE RETURN TRIP HOME. I BELIEVE IT HAPPENED WHEN I WAS DRIVING ON THE HIGHWAY. ONE SIDE OF EACH STRUT BROKE AND DENTED THE ROOF OF MY CAR. IF THE OTHER SIDE OF THE STRUTS FAILED THERE WOULD HAVE BEEN SOME DEVASTATION BEHIND ME AS LUMBER AND ROOF RACK PARTS WOULD HAVE FLOWN OFF BEHIND ME. I DO NOT KNOW THE EXACT WEIGHT OF THE LUMBER, BUT BASED ON THE QUANTITY I PURCHASED I CAN ASSUME IT WEIGHED AROUND 110-120 LBS. IF I KNEW THAT IT COULDN'T HANDLE 200LBS LIKE I WAS LED TO BELIEVE, I WOULD HAVE EASILY PUT ONE BOARD OR ALL OF THEM IN THE CAR INSTEAD OF THE ROOF RACK. I WOULD ALSO ASSUME THAT TOYOTA WOULD HAVE SOME SORT OF FACTOR OF SAFETY ON THE STRUTS. ALSO THE SIDE OF THE STRUTS THAT DIDN'T FAIL I ASSUME HAD AN INCREASED LOAD APPLIED TO THEM. THIS WOULD MAKE ME THINK THAT THERE COULD BE A PROBLEM IN THEIR MOLDING PROCESS AS WELL. THE PICTURE SHOWS THAT EACH ONE SAYS THAT IT CAN TAKE 100LBS EVENLY DISTRIBUTED. MY POINT IF MY TIRE SAYS 40PSI MAX THEN I DON'T FILL IT TO 10PSI BECAUSE THERE ARE 4 OF THEM. THE STRUTS ARE ALSO SEPARATE PIECES, WHAT IF I MIXED AND MATCHED OR ONLY HAD ONE ON THE CAR. ALSO THESE STRUTS ARE SOLD WITH THE RAV4 MODEL I GOT AND NOT PURCHASED AS AFTERMARKET OR AS AN ADD ON ITEM.
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
THE CAR IS EQUIPPED WITH AN AUTOMATIC TRANSMISSION. IT ROLLS BACK ON THE SLOPE WHEN THE BRAKE IS RELEASED. ROLLING BACK CONTINUES UNTIL THE BRAKE IS PRESSED AGAIN. THIS HAPPENS WHILE THE TRANSMISSION IS IN "DRIVE". IT ROLLS BACK USUALLY WHEN THE CAR IS DRIVEN AT THE LOW SPEED WITH FREQUENT TURNS. IRVINE AUTONATION TOYOTA LEA…
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THE CAR IS EQUIPPED WITH AN AUTOMATIC TRANSMISSION. IT ROLLS BACK ON THE SLOPE WHEN THE BRAKE IS RELEASED. ROLLING BACK CONTINUES UNTIL THE BRAKE IS PRESSED AGAIN. THIS HAPPENS WHILE THE TRANSMISSION IS IN "DRIVE". IT ROLLS BACK USUALLY WHEN THE CAR IS DRIVEN AT THE LOW SPEED WITH FREQUENT TURNS. IRVINE AUTONATION TOYOTA LEAD TECHNICIAN MARCO STATED THAT IT IS NORMAL FOR SOME CARS WITH A CERTAIN TRANSMISSION (760AE?). HE DEMONSTRATED WITH ANOTHER RAV4. THAT CAR ROLLED BACK ALSO UNTIL THE BRAKE IS PRESSED WHILE THE TRANSMISSION WAS IN "DRIVE". PROBLEM IS IT DOESN'T ROLL BACK ALWAYS. I EXPECT THE CAR WOULD NOT ROLL BACK WHILE IT'S IN "DRIVE". IT WOULD HIT THE CAR BEHIND IF I DON'T PRESS THE BRAKE FAST ENOUGH OR PRESS THE GAS PEDAL FAST ENOUGH. IT ACTS LIKE A MANUAL TRANSMISSION RATHER THAN AN AUTOMATIC TRANSMISSION. IF I DON'T HAVE FAST REACTION, DRIVING IN A HILLY AREA WOULD BE DANGEROUS.
Official recalls
423V734000 · Electrical SYSTEM:12V/24V/48V Battery
Nov 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.
15V144000 · Steering:electric Power Assist System
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.
15V011000 · Exterior Lighting; Trailer Hitches
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.
14V828000 · Equipment
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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