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2012 Toyota Tacoma

Owner reports · Recalls · Investigations

Similar to other model years

Owner complaints for the 2012 Toyota Tacoma do not stand out strongly from the model-year median of 228.5.

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When problems were reported

Mileage at the reported incident

261 reports with mileage · 34 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.

  • Engine. Review the 122 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Fuel/propulsion System. Review the 52 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Power Train. Review the 35 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →

NHTSA owner reports · September 18, 2026 snapshot.

16 crash reports0 fire reports6 injury reports

What owners actually said

295 reports
48,000 miles · Sep 28, 2017
EngineUnknown Or Other

I WAS PULLING OUT ON TO THE HIGHWAY AND MY TRUCK FAILED TO EXCEED 30 MPH WITH ONCOMING TRAFFIC WHICH NEARLY CAUSED AN ACCIDENT. UPON INSPECTION BY MY TOYOTA DEALERSHIP, THEY EXPLAINED THAT MY SECONDARY AIR INJECTION VALVES WERE STUCK OPEN (P2440, P2442) WHICH CAUSED THE TRUCK TO LOSE ALL POWER. I WAS THEN TOLD THAT SINCE I AM …

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I WAS PULLING OUT ON TO THE HIGHWAY AND MY TRUCK FAILED TO EXCEED 30 MPH WITH ONCOMING TRAFFIC WHICH NEARLY CAUSED AN ACCIDENT. UPON INSPECTION BY MY TOYOTA DEALERSHIP, THEY EXPLAINED THAT MY SECONDARY AIR INJECTION VALVES WERE STUCK OPEN (P2440, P2442) WHICH CAUSED THE TRUCK TO LOSE ALL POWER. I WAS THEN TOLD THAT SINCE I AM NO LONGER UNDER WARRANTY (MY TRUCK IS ONLY 5 YEARS OLD WITH 48,000 MILES ON IT) THAT TOYOTA WOULD NOT COVER THE 2,000 DOLLAR COST TO HAVE THE PART REPLACED. UPON FURTHER RESEARCH, COUNTLESS OTHERS WERE HAVING THE SAME ISSUE. THE TOYOTA TUNDRA ALSO HAD THIS ISSUE AND AN EXTENDED WARRANTY WAS OFFERED FOR THOSE VEHICLES. SINCE TOYOTA KNOWS THIS IS AN ISSUE IT IS MY BELIEF THAT THEY SHOULD STAND BY THEIR PRODUCT AND FIX THE DEFECTIVE PART WHICH IS A HUGE SAFETY ISSUE AS I FOUND OUT. FURTHERMORE, THERE IS NO REASON THIS EMISSIONS PART SHOULD EVER SHUT DOWN THE POWER TO THE TRUCK WHILE DRIVING. THANK YOU FOR YOUR TIME.

NHTSA ODI #11030390

97,300 miles · Sep 27, 2017
EngineFuel/propulsion System

ERROR CODE P2442 SECONDARY AIR INJECTION VALVE STUCK OPEN. TRUCK IMMEDIATELY GOES INTO "LIMP' MODE AND WILL NOT ACCELERATE OVER 20MPH. EXTREMELY UNSAFE TO HAVE THE VEHICLE DECELERATE ON A HIGHWAY FOR A KNOWN ISSUE THAT HAS PROMPTED WARRANTY EXTENSIONS ON TOYOTA TUNDRA'S.

NHTSA ODI #11030179

41,000 miles · Sep 9, 2017
Engine

FAULT CODES P2440 AND P2442, POWERTRAIN - AUXILIARY EMISSION CONTROLS. AIR PUMP FAILING AT 41,000 MILES. DEALER REPAIR COST IS $1,900. VEHICLE GOES IN TO "LIMP MODE" WHEN STARTED, THAT DRASTICALLY REDUCES POWER.

NHTSA ODI #11022476

77,000 miles · Sep 2, 2017
Electronic Stability Control (esc)Service Brakes

THE ABS ACTUATES PREMATURELY DURING CORNERING ON FREEWAY ON/OFF RAMPS AND IN CORNERS RESULTING IN SUSPENSION DIVE, AN UNDER STEER CONDITION, AND LOSS OF VEHICLE CONTROL. THIS OCCURS WHEN THE VEHICLE IS IN MOTION AT POSTED SPEED LIMITS ON DRY PAVEMENT. I HAVE CONTACTED TOYOTA/BEEN TO THE DEALERSHIP SEVERAL TIMES ABOUT THIS ISSU…

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THE ABS ACTUATES PREMATURELY DURING CORNERING ON FREEWAY ON/OFF RAMPS AND IN CORNERS RESULTING IN SUSPENSION DIVE, AN UNDER STEER CONDITION, AND LOSS OF VEHICLE CONTROL. THIS OCCURS WHEN THE VEHICLE IS IN MOTION AT POSTED SPEED LIMITS ON DRY PAVEMENT. I HAVE CONTACTED TOYOTA/BEEN TO THE DEALERSHIP SEVERAL TIMES ABOUT THIS ISSUE WITH NO RESOLUTION. THEY CLAIM THAT THE LEVELING KIT AND AT TIRES ARE TO BLAME. I RELATED THAT I HAD THIS ISSUE WITH THE TRUCK WHEN IT WAS BRAND NEW WITH NO MODIFICATIONS.

NHTSA ODI #11021214

105,000 miles · Sep 2, 2017
EnginePower TrainVehicle Speed Control

WHILE COMMUTING TO WORK THE ENGINE LIGHT AND TRACTION CONTROL LIGHT CAME ON, CAUSING MY TRUCK TO SLOW DOWN, VERY SLOW. IT WOULD NOT LET ME ACCELERATE AND DISABLED MY PROGRESS TO AROUND 2000 RPMS. THIS COULD HAVE BEEN A VERY SERIOUS OR A DANGEROUS SITUATION ESPECIALLY IF I WAS TOWING A LOAD OR IN A MAJOR TRAFFIC SITUATION. CODES…

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WHILE COMMUTING TO WORK THE ENGINE LIGHT AND TRACTION CONTROL LIGHT CAME ON, CAUSING MY TRUCK TO SLOW DOWN, VERY SLOW. IT WOULD NOT LET ME ACCELERATE AND DISABLED MY PROGRESS TO AROUND 2000 RPMS. THIS COULD HAVE BEEN A VERY SERIOUS OR A DANGEROUS SITUATION ESPECIALLY IF I WAS TOWING A LOAD OR IN A MAJOR TRAFFIC SITUATION. CODES - 2440 AND 2442 WERE THE CAUSES OF THIS SCARY ACCOUNT.

NHTSA ODI #11021153

49,000 miles · Aug 13, 2017
Engine

SECONDARY AIR INJECTION SWITCHING VALVE MALFUNCTION RELATED TO EMISSIONS. CODE P2440 & P2442,

NHTSA ODI #11014957

49,652 miles · Aug 5, 2017
Electronic Stability Control (esc)Engine

AT START UP "CHECK ENGINE" AND "TRAC OFF" LIGHTS WERE ON. TRUCK HAD NO ACCELERATION AND TRANSMISSION WOULD NOT SHIFT. I TOOK THE CAR TO THE DEALERSHIP AND DIAGNOSTIC CODES P2440 AND P2442 WERE DETECTED. DEALER HAD TO REPLACE THE AIR INJECTION SYSTEM BANK 1 AND BANK 2. DURING RESEARCH, I DISCOVERED NUMEROUS OTHER OWNERS OF 2012 …

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AT START UP "CHECK ENGINE" AND "TRAC OFF" LIGHTS WERE ON. TRUCK HAD NO ACCELERATION AND TRANSMISSION WOULD NOT SHIFT. I TOOK THE CAR TO THE DEALERSHIP AND DIAGNOSTIC CODES P2440 AND P2442 WERE DETECTED. DEALER HAD TO REPLACE THE AIR INJECTION SYSTEM BANK 1 AND BANK 2. DURING RESEARCH, I DISCOVERED NUMEROUS OTHER OWNERS OF 2012 TACOMA'S COMPLAING ABOUT THE SAME ISSUE. SOME EVEN LOST POWER WHILE DRIVING. ALSO, THE TUNDRA APPARENTLY HAD A SIMILAR ISSUE BEING REPORTED

NHTSA ODI #11013036

68,000 miles · Aug 5, 2017
Fuel/propulsion System

LIKE MANY OTHERS, MY 2012 TACOMA SUDDENLY LOST POWER ON THE HIWAY. REFUSED TO GO ABOVE 40 OR SO MPH. OTHER CARS HAD TO SLAM ON BRAKES TO AVOID ME. TOOK IT TO THE DEALER AND THEY WANTED NEARLY $2000.00 TO REPLACE THE SAME PARTS THAT HAVE BEEN IDENTIFIED IN THE TUNDRAS AS BEING DEFECTIVE. SECONDARY AIR INJECTION STUCK OPEN. T…

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LIKE MANY OTHERS, MY 2012 TACOMA SUDDENLY LOST POWER ON THE HIWAY. REFUSED TO GO ABOVE 40 OR SO MPH. OTHER CARS HAD TO SLAM ON BRAKES TO AVOID ME. TOOK IT TO THE DEALER AND THEY WANTED NEARLY $2000.00 TO REPLACE THE SAME PARTS THAT HAVE BEEN IDENTIFIED IN THE TUNDRAS AS BEING DEFECTIVE. SECONDARY AIR INJECTION STUCK OPEN. THE CODES ARE P2440 AND P2442. THIS IS A SAFETY HAZARD AS THE VEHICLE SUDDENLY LOSES POWER. TOYOTA ISSUED A TSB AND EXTENDED THE WARRANTY TO 150K FOR THE TUNDRA BUT NOT THE TACOMA. SAME PARTS! MY TACOMA WAS IN MOTION WHEN SUDDENLY LOST POWER. THIS IS A SAFETY ISSUE. CHECK OUT CARCOMPLAINTS.COM

NHTSA ODI #11012975

46,925 miles · Aug 2, 2017
Fuel/propulsion System

SECONDARY AIR PUMP FAILED AT 47,000 MILES, SHORTLY AFTER WARRANTY EXPIRED. IT FAILED AS I WAS PULLING OUT ONTO A MAJOR FAST-MOVING HIGHWAY AND PROMPTLY WENT INTO "LIMP" MODE, LIMITING ACCELERATION. IT TOOK OVER A HALF MILE TO GET THE VEHICLE TO 40 MPH. MEANWHILE, VEHICLES BEHIND ME WERE BRAKING ABRUPTLY TO AVOID COLLIDING WITH M…

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SECONDARY AIR PUMP FAILED AT 47,000 MILES, SHORTLY AFTER WARRANTY EXPIRED. IT FAILED AS I WAS PULLING OUT ONTO A MAJOR FAST-MOVING HIGHWAY AND PROMPTLY WENT INTO "LIMP" MODE, LIMITING ACCELERATION. IT TOOK OVER A HALF MILE TO GET THE VEHICLE TO 40 MPH. MEANWHILE, VEHICLES BEHIND ME WERE BRAKING ABRUPTLY TO AVOID COLLIDING WITH ME. AS I UNDERSTAND IT THE SECONDARY AIR PUMP IS PART OF THE EMISSION CONTROL SYSTEM AND I DON'T BELIEVE THAT THIS SHOULD EFFECT THE PERFORMANCE OF THE ENGINE IN THIS MANNER. THIS SEEMS MORE LIKE A SOFTWARE INDUCED FAILURE, WHICH, IN THIS CASE, CAUSED A POTENTIALLY DANGEROUS SITUATION. AFTER SOME BACK AND FORTH TOYOTA AGREED TO REFUND ME 1/2 OF THE $2500 THAT I WAS CHARGED FOR THE REPAIR. UPON SEARCHING THE INTERNET, I FOUND DOZENS OF INSTANCES OF THIS FAILURE ON 2012 TACOMA'S WITH SIMILAR MILEAGE.

NHTSA ODI #11012395

62,000 miles · Jul 29, 2017
Electrical SystemSteering

HORN QUIT WORKING, ONLY WORKS WHEN THE WHEEL IS TURNED TO THE LEFT, FUSES ARE GOOD AND SO ARE THE RELAYS.

NHTSA ODI #11011463

Official recalls

7

17V425000 · Equipment; Structure:body:hood:hinge And Attachments

Jul 3, 2017

Southeast Toyota Distributors, LLC (SET) is recalling certain 2011-2016 Toyota Tacoma and 4Runner vehicles equipped with accessory hood scoops installed by SET or SET dealers. The adhesive attaching the hood scoop may weaken, allowing the hood scoop to detach from the vehicle.

Consequence & remedy

Consequence: If the hood scoop detaches, it may become a road hazard, increasing the risk of a crash.

Remedy: SET will notify owners, and dealers will mechanically fasten the scoop to the hood, free of charge. The recall began on September 1, 2017. Owners may contact SET customer service at 1-954-429-2000. SET's number for this recall is SET17B.

Additional source detail variants (2)

Equipment

Southeast Toyota Distributors, LLC (SET) is recalling certain 2011-2016 Toyota Tacoma and 4Runner vehicles equipped with accessory hood scoops installed by SET or SET dealers. The adhesive attaching the hood scoop may weaken, allowing the hood scoop to detach from the vehicle.

Consequence: If the hood scoop detaches, it may become a road hazard, increasing the risk of a crash.

Remedy: SET will notify owners, and dealers will mechanically fasten the scoop to the hood, free of charge. The recall began on September 1, 2017. Owners may contact SET customer service at 1-954-429-2000. SET's number for this recall is SET17B.

Structure:body:hood:hinge And Attachments

Southeast Toyota Distributors, LLC (SET) is recalling certain 2011-2016 Toyota Tacoma and 4Runner vehicles equipped with accessory hood scoops installed by SET or SET dealers. The adhesive attaching the hood scoop may weaken, allowing the hood scoop to detach from the vehicle.

Consequence: If the hood scoop detaches, it may become a road hazard, increasing the risk of a crash.

Remedy: SET will notify owners, and dealers will mechanically fasten the scoop to the hood, free of charge. The recall began on September 1, 2017. Owners may contact SET customer service at 1-954-429-2000. SET's number for this recall is SET17B.

14V475000 · Equipment:other:labels

Aug 4, 2014

Toyota Motor Engineering & Manufacturing (Toyota) is recalling certain model year 2008-2014 FJ Cruiser and Tacoma vehicles equipped with accessory wheels and tires installed by Toyota or dealers prior to the vehicle's first sale. The affected vehicles may list incorrect spare tire size and/or cold tire inflation information on the tire placard. As such, these vehicles fail to comply with Federal Motor Vehicle Safety Standard No. 110, "Tire Selection and Rims for Passenger Cars."

Consequence & remedy

Consequence: If the spare tire is inflated to the incorrect pressure provided on the placard, tire failure may occur while it is being driven on, increasing the risk of a crash.

Remedy: For the involved vehicles, overlay stickers to correct the tire placard will either be mailed to owners or provided to dealers for placement over the incorrect information on the placard. The recall is expected to begin in September 2014. Owners may contact Toyota customer service at 1-800-331-4331.

14V054000 · Electronic Stability Control (esc); Service Brakes, Hydraulic:antilock/traction Control/electronic Limited Slip:control Unit/module

Feb 12, 2014

Toyota is recalling certain model year 2012 and 2013 Toyota Tacoma and Lexus RX350 vehicles and certain model year 2012 Toyota Rav4 vehicles. In the affected vehicles, the brake system contains a brake actuator that adjusts the fluid pressure of each wheel cylinder. An electrical component within the actuator may experience an increased resistance resulting in the illumination of various warning lights, including those for the Vehicle Stability Control (VSC) system, Antilock Brake System (ABS), and Traction Control system.

Consequence & remedy

Consequence: If this occurs, these systems could become inoperative, reducing the directional control assistance, increasing the risk of a crash.

Remedy: Toyota will notify owners, and Toyota and Lexus dealers will update the software for the Skid Control electronic control unit, free of charge. The recall began on March 28, 2014. Owners may contact Toyota at 1-800-331-4331.

Additional source detail variants (2)

Electronic Stability Control (esc)

Toyota is recalling certain model year 2012 and 2013 Toyota Tacoma and Lexus RX350 vehicles and certain model year 2012 Toyota Rav4 vehicles. In the affected vehicles, the brake system contains a brake actuator that adjusts the fluid pressure of each wheel cylinder. An electrical component within the actuator may experience an increased resistance resulting in the illumination of various warning lights, including those for the Vehicle Stability Control (VSC) system, Antilock Brake System (ABS), and Traction Control system.

Consequence: If this occurs, these systems could become inoperative, reducing the directional control assistance, increasing the risk of a crash.

Remedy: Toyota will notify owners, and Toyota and Lexus dealers will update the software for the Skid Control electronic control unit, free of charge. The recall began on March 28, 2014. Owners may contact Toyota at 1-800-331-4331.

Service Brakes, Hydraulic:antilock/traction Control/electronic Limited Slip:control Unit/module

Toyota is recalling certain model year 2012 and 2013 Toyota Tacoma and Lexus RX350 vehicles and certain model year 2012 Toyota Rav4 vehicles. In the affected vehicles, the brake system contains a brake actuator that adjusts the fluid pressure of each wheel cylinder. An electrical component within the actuator may experience an increased resistance resulting in the illumination of various warning lights, including those for the Vehicle Stability Control (VSC) system, Antilock Brake System (ABS), and Traction Control system.

Consequence: If this occurs, these systems could become inoperative, reducing the directional control assistance, increasing the risk of a crash.

Remedy: Toyota will notify owners, and Toyota and Lexus dealers will update the software for the Skid Control electronic control unit, free of charge. The recall began on March 28, 2014. Owners may contact Toyota at 1-800-331-4331.

13V494000 · Tires:temporary/emergency Spare Tire

Oct 17, 2013

Southeast Toyota Distributors, LLC (SET) is recalling certain model year 2012-2013 Tacoma vehicles equipped with 18" Maverick Alloy Wheels. In the affected vehicles, the spare tire requires the use of a different style of lug nut to attach it to the vehicle than the other wheels use. These lug nuts were not provided with the vehicle.

Consequence & remedy

Consequence: If the spare tire/wheel is installed on the vehicle using the lug nuts from another wheel, damage to the wheel could result and may eventually lead to a loose wheel, increasing the risk of a crash.

Remedy: SET will notify owners, and dealers will: (a) Install a Warning Label on the spare tire/wheel, (b) supply a bag containing proper spare wheel lug nuts, and (c) place an Owner's Manual Addendum in the vehicle's glove box. The recall began on January 23, 2014. Owners may contact SET at 1-954-429-2000.

13V123000 · Equipment:other:labels

Apr 9, 2013

Southeast Toyota is recalling certain model year 2008 and 2010-2013 Toyota Tundra, 2010-2012 Rav4, 2012 Toyota Sequoia, 2010-2011 Toyota Corolla, 2010-2011 Toyota Camry and Camry Hybrid, 2010-2013 Toyota Highlander and Highlander Hybrid, 2010-2013 Toyota FJ Cruiser, 2011 Toyota Land Cruiser, 2010-2013 Toyota Venza, 2010-2011 Toyota 4Runner, 2010-2013 Toyota Tacoma, 2011-2012 Toyota Sienna, 2012 Toyota Prius, 2013 Scion FR-S, 2011 Scion XD, 2011 Scion XB, and 2012 Scion TC vehicles. These vehicles were sold with labels that were outside the allowable one percent of accuracy of actual weight added. Thus, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard (FMVSS) Number 110, "Tire Selection and Rims."

Consequence & remedy

Consequence: An inaccurate label could lead to owners overloading their vehicles and tires. An overloaded vehicle can result in a tire failure which may result in a vehicle crash, personal injury, or property damage.

Remedy: Southeast Toyota will notify owners and provide a corrected label with instructions concerning its installation. A small group of the affected vehicles will need additonal remedies which are still being developed. The recall began on May 28, 2013. Owners may contact Southeast Toyota at 1-800-301-6859.

13V014000 · Air Bags:frontal:sensor/control MODULE-INACTIVE ; Seats

Jan 16, 2013

Southeast Toyota Distributors, LLC (SET) is recalling certain models interspersed through model years 2009 through 2013 as follows: model year 2009-2012 Tacoma, 4Runner, Camry, Camry Hybrid, Prius, and RAV4; model year 2009-2010 Avalon, FJ Cruiser, and Highlander Hybrid; model year 2010-2013 model year Corolla, Sienna and Tundra; model year 2009-2013 Highlander and Venza; model year 2012 Prius V; and model year 2010-2012 Sequoia. During modification by SET to include accessories such as leather seat covers, seat heaters or headrest DVD systems, these vehicles may not have had the passenger seat occupant sensing system calibration tested. Without passing the calibration test, the occupant sensing system may not operate as designed.

Consequence & remedy

Consequence: If the front passenger seat occupant sensing system is out of calibration, the front passenger airbags may not deploy or they may deploy inappropriately for the passenger's size and position. This could increase the risk of personal injury during the event of a vehicle crash necessitating airbag deployment.

Remedy: Southeast Toyota will notify owners, and dealers will test the sensitivity of the occupant detection sensors, and recalibrate them as necessary. The recall began on March 21, 2013. Owners may contact Southeast Toyota at 1-800-301-6859.

Additional source detail variants (2)

Seats

Southeast Toyota Distributors, LLC (SET) is recalling certain models interspersed through model years 2009 through 2013 as follows: model year 2009-2012 Tacoma, 4Runner, Camry, Camry Hybrid, Prius, and RAV4; model year 2009-2010 Avalon, FJ Cruiser, and Highlander Hybrid; model year 2010-2013 model year Corolla, Sienna and Tundra; model year 2009-2013 Highlander and Venza; model year 2012 Prius V; and model year 2010-2012 Sequoia. During modification by SET to include accessories such as leather seat covers, seat heaters or headrest DVD systems, these vehicles may not have had the passenger seat occupant sensing system calibration tested. Without passing the calibration test, the occupant sensing system may not operate as designed.

Consequence: If the front passenger seat occupant sensing system is out of calibration, the front passenger airbags may not deploy or they may deploy inappropriately for the passenger's size and position. This could increase the risk of personal injury during the event of a vehicle crash necessitating airbag deployment.

Remedy: Southeast Toyota will notify owners, and dealers will test the sensitivity of the occupant detection sensors, and recalibrate them as necessary. The recall began on March 21, 2013. Owners may contact Southeast Toyota at 1-800-301-6859.

Air Bags:frontal:sensor/control MODULE-INACTIVE

Southeast Toyota Distributors, LLC (SET) is recalling certain models interspersed through model years 2009 through 2013 as follows: model year 2009-2012 Tacoma, 4Runner, Camry, Camry Hybrid, Prius, and RAV4; model year 2009-2010 Avalon, FJ Cruiser, and Highlander Hybrid; model year 2010-2013 model year Corolla, Sienna and Tundra; model year 2009-2013 Highlander and Venza; model year 2012 Prius V; and model year 2010-2012 Sequoia. During modification by SET to include accessories such as leather seat covers, seat heaters or headrest DVD systems, these vehicles may not have had the passenger seat occupant sensing system calibration tested. Without passing the calibration test, the occupant sensing system may not operate as designed.

Consequence: If the front passenger seat occupant sensing system is out of calibration, the front passenger airbags may not deploy or they may deploy inappropriately for the passenger's size and position. This could increase the risk of personal injury during the event of a vehicle crash necessitating airbag deployment.

Remedy: Southeast Toyota will notify owners, and dealers will test the sensitivity of the occupant detection sensors, and recalibrate them as necessary. The recall began on March 21, 2013. Owners may contact Southeast Toyota at 1-800-301-6859.

12V158000 · Equipment:other:labels

Apr 10, 2012

GULF STATES TOYOTA (GST) IS RECALLING CERTAIN MODEL YEAR 2012 TACOMA TRUCKS. THE TIRE AND LOADING INFORMATION PLACARD ON EACH VEHICLE CONTAINS INACCURATE SPARE TIRE SIZE AND COLD INFLATION PRESSURE INFORMATION. THUS, THESE VEHICLES FAIL TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 110,”TIRE SELECTION AND RIMS.”

Consequence & remedy

Consequence: AN INCORRECT PLACARD COULD LEAD TO IMPROPER SPARE TIRE USE OR REPLACEMENT WHICH COULD RESULT IN A TIRE FAILURE, INCREASING THE RISK OF A CRASH.

Remedy: GST WILL NOTIFY OWNERS, AND SEND EACH OWNER A CORRECTED PLACARD, FREE OF CHARGE. THE SAFETY RECALL BEGAN ON JUNE 5, 2012. OWNERS MAY CONTACT GULF STATES TOYOTA, INC. AT 1-713-744-3465.

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

1

EA19001 · Electrical Overstress

Opened Apr 19, 2019 · Closed Sep 19, 2024

Status: closed (inferred from source dates) · Air Bags: Air Bag/restraint Control Module

The Office of Defects Investigation (ODI) opened this investigation to determine if the failure of airbags to deploy during severe crashes, in certain vehicles, was the result of a safety related defect.  During the investigation a complex failure was studied that can result in non-deployment of subject vehicle air bags and other restraint system devices in severe crash events. The subject vehicles may be equipped with an airbag control unit (ACU) for the supplemental restraint system (SRS) Electronic Control Unit (ECU) manufactured by ZF-TRW.  The ECU receives signals from crash sensors mounted in the vehicle and deploys the vehicle air bags and seat belt pretensioners in accordance with manufacturer design specifications.  The ECU in the subject vehicles contains a model DS84 application-specific integrated circuit (ASIC) which controls the communication of the crash sensor signal, firing commands (i.e., when to deploy the airbag(s) and/or pretensioners), and fault information (e.g., diagnostic trouble codes). In September 2016, FCA announced recall 16V-668 for certain model year (MY) 2010 to 2014 Chrysler, Dodge and Jeep products manufactured with the subject ZF-TRW ACU.  In this recall, FCA discussed an EOS condition that resulted in a failure of the subject DS84 ASIC, which caused air bag non-deployment.  FCA noted that the defect condition had only been observed in vehicles equipped with sensor harnessing routed across the front of the vehicle.  Other FCA vehicles that also used the subject ACU, but were not equipped with cross-car harnessing, had not experienced EOS failures, despite similar time in service. During the course of this investigation, ODI sent two separate Information Request (IR) letters to six vehicle manufactures (including FCA, Hyundai, Honda, Kia, Mitsubishi, and Toyota) and one IR letter to ZF-TRW.  These IR letters resulted in ODI receiving comprehensive data from these manufacturers and suppliers. Studies of this data found that the DS84 ASIC does not have sufficient protection against negative electrical transients or electrical overstress (“EOS”) that can be generated in certain severe crashes.  An electrical transient occurs when the electrical power supplied to a circuit changes momentarily over a short duration of time.   In these severe crash cases, the crash sensors and other powered wiring can be damaged and short circuited so as to create a negative electrical transient of sufficient intensity and duration (that are outside the vehicle manufacturer's specification) to damage the ASIC before the restraint device deployment signal is received by the SRS ECU.  This damaged signal can lead to incomplete or nondeployment of the air bags and/or pretensioners.  Airbag non-deployment and/or lack of pretensioner operation can increase the risk or severity of injury in a crash.A total of 8 fatalities and 14 injuries were associated with known EOS events. The common element in all investigated manufacturers vehicles is the SRS ECU containing a DS84 ASIC manufactured by ZF-TRW.  The risk associated with the ASIC is equally shared among all OEMS involved in the investigation.  The actual real-world risk can be mitigated by other factors which were assessed by ODI during this investigation. The first mitigating factor involves protections built into the ACU design which protect the DS84 ASIC from damage.  There are multiple strategies and levels of protection employed by different OEMs that provide effective EOS mitigation.  The two most common strategies at the ACU level are circuit protection diodes on the remote senor signal lines, and current limiting resistors that protect critical components. The second mitigating factor is found at the vehicle level and involves the location and routing of the wires leading from the crash sensors to the SRS ECU.  If the wires are well protected in a crash and are not routed with other power wires carrying large currents, the risk for an EOS event is significantly reduced or eliminated. These design specific factors combine to produce a spectrum of risk for the vehicles equipped with ACUs using the DS84 ASIC.  Given the many of years of field exposure, it is possible to divide the subject population into two groups; vehicles which have experienced EOS events, and vehicles which have not experienced EOS field events. Four of the six OEMs involved in this investigation have experienced EOS field events on at least one of their models equipped with a DS84 ASIC.  All vehicle models (including the Toyota models identified in the Failure Report Summary of the opening resume for this investigation) with field events have been recalled.  In an abundance of caution, ODI kept this investigation open five years to monitor field performance and did not identify any field events on vehicles not included in existing safety recalls. Given the spectrum of risk identified in this investigation and that all vehicles with a demonstrated unreasonable risk have been recalled, ODI is closing this investigation. ODI is closing this investigation with the following manufacturer safety recalls: 16V-668, 18E-043, 18V-137, 18V-363, and 20V-024.  With the recall actions taken by the subject vehicle and equipment manufacturers, this investigation is closed. The closing of this investigation does not constitute a finding by NHTSA that a safety-related defect does not exists on other model or model year vehicles outside of the recall scopes. The agency reserves the right to take further action if warranted by the circumstances.