2023 TOYOTA RAV4

3 recalls, 268 complaints - 48 TSBs - 5/5 safety rating

BACK OVER PREVENTION:DISPLAY FUNCTION

Defect Description

Toyota Motor Engineering & Manufacturing (Toyota) is recalling certain 2022-2026 Toyota, Lexus, and Subaru Solterra vehicles equipped with a Panoramic View Monitor (PVM) system. Please see the recall report for a complete list of models. A software error may cause the rearview camera to freeze or di... Read more

Consequence

A rearview camera that fails to display an image can reduce the driver's view behind the vehicle, increasing the risk of a crash.

Remedy

Dealers will update the parking assist software, free of charge. Owner letters were mailed January 2, 2026. Owners may contact Toyota's customer service at 1-800-331-4331. Toyota's numbers for this recall are 25TB13 and 25LB06. Subaru's number for this recall is WRE25.

1,024,407 vehicles affected

Manufacturer: Toyota Motor Engineering & Manufacturing

ELECTRICAL SYSTEM: INSTRUMENT CLUSTER/PANEL

Defect Description

Toyota Motor Engineering & Manufacturing (Toyota) is recalling certain 2023-2024 Toyota Venza, 2023-2025 RAV4 Prime, RAV4, Highlander, GR Corolla, Crown, 2024-2025 Lexus TX, LS, Toyota Tacoma, Grand Highlander, and 2025 Lexus RX, Toyota Crown Signia, Camry, RAV 4 Plug-in Hybrid (PHEV), and 4 Runner ... Read more

Consequence

An instrument panel display that does not show critical information can increase the risk of a crash or injury.

Remedy

Dealers will update the instrument panel software over-the-air (OTA) for non-PHEV vehicles, free of charge. For PHEV vehicles, dealers will inspect the instrument panel assembly, and either replace it, or update the software, free of charge. Owner letters were mailed December 5, 2025. Additional let... Read more

591,377 vehicles affected

Manufacturer: Toyota Motor Engineering & Manufacturing

TIRES:VALVE

Defect Description

Gulf States Toyota, Inc. (GST) is recalling certain 2023 Toyota RAV4 vehicles equipped with 17" black alloy accessory wheels. During installation of the alloy wheels, the tire valve stem may have been improperly installed or damaged. In addition, the load carrying capacity label may state the inco... Read more

Consequence

A damaged or improperly installed valve stem may allow air to leak and/or the tires to be underinflated, increasing the risk of tire failure and a crash.

Remedy

Dealers will inspect and, if necessary, replace the wheel valve stems and replace the load carrying capacity modification labels, free of charge. Owner notification letters were mailed on August 18, 2023. Owners may contact GST customer service at 1-800-444-1074. GST's number for this recall is 2... Read more

195 vehicles affected

Manufacturer: Gulf States Toyota, Inc.

Complaint Statistics

268 total complaints 13 crashes 2 fires 21 injuries

Top Reported Components

Component	Complaints
ENGINE	49
UNKNOWN OR OTHER	31
ELECTRICAL SYSTEM	27
POWER TRAIN	27
STEERING	15
SERVICE BRAKES	10
FUEL/PROPULSION SYSTEM	9
FORWARD COLLISION AVOIDANCE: WARNINGS	8
VEHICLE SPEED CONTROL	8
STRUCTURE:BODY	7

Incident date: May 1, 2026

The backup camera display only works intermittently. About 75% of the time the screen is blank when I put it into reverse

Incident date: Aug 30, 2026

The contact owns a 2023 Toyota Rav4 equipped with Firestone Tires, Tire Line: Destination LE2, Tire Size: 225/65/R17, DOT Number: [XXX]. The contact stated that while driving on [XXX], the red light illuminated and there was an abnormal rumbling sound. The contact pulled over at the exit and became ... Read more

Incident date: Aug 3, 2026

The vehicle experienced a sudden, severe loss of vehicle control while driving twice. Without any warning lights, dash indicators, or stored error codes, it began violently surging and decelerating uncontrollably around 20 mph with severe bucking. My [XXX] daughter was driving. Fortunately, this occ... Read more

Incident date: Aug 31, 2026

Front forward camera unavailable, World wide shortage of part. No known date of supply.

Incident date: Aug 31, 2026

Front forward camera unavailable, World wide shortage of part. No known date of supply.

Incident date: Aug 3, 2026

Incident date: Aug 31, 2026

Front forward camera unavailable, World wide shortage of part. No known date of supply.

Incident date: Jul 15, 2026

Description of the Defect:I am reporting a premature and dangerous failure of the electronic door lock actuators on my 2023 Toyota RAV4 Hybrid SE. The issue began with the driver’s door lock intermittently failing to respond to the key fob and the internal master switch. Shortly after, the rear pa... Read more

Incident date: Aug 12, 2026

The contact owns a 2023 Toyota Rav4. The contact stated that while her husband was driving approximately 25 MPH, there was an abnormal bang coming from the vehicle, and the rear glass shattered without impact. The vehicle was taken to a local dealer, and the contact was informed that the damage was ... Read more

Incident date: Aug 6, 2026

On August 6 2026, my RAV4 just cut off at the traffic light. The car was completely dead. I was unable to unlock the trunk but the doors did open. The vehicle was towed to the local dealership. The tow truck man hooked up his portable car charger and the car started. On August 8, 2026 the car cut o... Read more

Incident date: Aug 6, 2026

The front driveshaft universal joint failed causing the drive shaft to bust a hole in the engine and crack the transmission. There was no knocking noise prior to failure. It suddenly failed, disengaged and caused damage. I was told by service manager the u-bolt must have been defective to have faile... Read more

Incident date: Aug 6, 2026

all my lights came on for all of these and break Adaptive Cruise Control Automatic Emergency Braking Blind Spot Warning Forward Collision Warning Lane Departure Warning Lane Keeping Assistance Parking Collision Warning Rear Cross Traffic Warning

Incident date: Aug 6, 2026

Incident date: May 19, 2026

While traveling at highway speeds with my family on our way to a college visit, the vehicle suffered a sudden, catastrophic loss of propulsion due to a complete breach of the automatic transmission oil cooler lines (Part numbers: 3QF317801C and 3QF317820C). The breach caused hot, pressurized transmi... Read more

Incident date: Jul 31, 2026

Honestly since I took delivery the vehicle I did notice a clunking sound every time I would turn into a steep driveway. I reported the problem to Tesla on multiple occasions and they either could not replicate the sound or find the problem when they inspected the vehicle. So I lived with the on and ... Read more

Incident date: Jul 31, 2026

On or about XXX I brought my vehicle into the dealership as my 2020 Hyundai palisade suffered a severe, sudden engine malfunction while driving at highway speeds. The vehicle began shaking violently, losing power, and making loud mechanical noises forcing me to navigate dangerous highway traffic to ... Read more

Incident date: Jul 24, 2026

The contact owns a 2018 Toyota Camry. The contact stated that while her son was driving at an undisclosed speed, the check engine warning light illuminated, and the message “See Dealer” was displayed. The vehicle was taken to a dealer, but the dealer was unable to determine the cause of the fail... Read more

Incident date: Jul 19, 2026

There is frequently a smell of exhaust inside the cabin upon starting the engine before driving. It is concerning that exhaust may be leaking into the cabin leading to potential injuries. The vehicle has not been inspected for this issue specifically but has been through multiple general inspections... Read more

Incident date: Jul 11, 2026

On about 5 occasions, and at a stop light, the auto stop did not re-engage when I attempted to move forward. The first time it happened I only had about 28k miles on it and I was making a left at a light in [XXX]. On another occasion, about 7 months ago, I was driving in [XXX] and the vehicle shu... Read more

Incident date: Jul 16, 2026

Date: Sunday, XXX at approximately 10:30 AM Location: LAZ Parking Garage, [XXX] Details: While exiting the parking garage at approximately 5 MPH, the vehicle suddenly and unexpectedly engaged automatic braking, causing the vehicle to make contact with a yellow pole in the garage. As a result of the ... Read more

Crash

Incident date: May 20, 2026

The affected component is the powertrain system in my 2020 Ford EcoSport. The vehicle has experienced repeated powertrain-related failures and is available for inspection upon request. In May 2025, the vehicle required a full engine replacement, yet I am continuing to experience serious powertrain-r... Read more

Incident date: May 20, 2026

Incident date: Jul 6, 2026

The engine lifters and camshaft started to fail at 114,000 miles. I had to have it repaired at a dealership and it cost over $10,000. I had completed all recommended maintenance prior to the failure. 500 miles after that repair was completed, my transmission overheated and completely left me strande... Read more

Incident date: Jul 6, 2026

The contact owns a 2020 Ford Escape. The contact stated that the vehicle was taken to a local dealer for NHTSA Campaign Number: 26V123000 (Back Over Prevention). The dealer performed the software reprogramming; however, a week after the recall repair, the display screen and rearview camera shut off ... Read more

1 injured

Incident date: Jul 5, 2026

I'm filing an urgent safety complaint regarding a series of severe defects in my 2026 Volkswagen Tiguan (VIN: [XXX]) that pose immediate, life-threatening hazards. On XXX, I took delivery of the vehicle, which was refueled by the dealership. By XXX, with temperatures soaring to 104°F, I encounter... Read more

Incident date: Jul 4, 2026

Lane keeping, adaptive cruise control, auto high beam lights, forward collision warning. It is available for inspection. This is the whole reason we went with this car was the safety features. Now none of the forward Saftey features are currently working because of the front safety camera failure. H... Read more

Incident date: Jul 4, 2026

I had gotten the free trial of FSD (full self driving) from Tesla in 2024. I used it with a friend to take us to the zoo. It drove there perfectly with no issues & even backed itself in the parking spot. When time to leave, my friend suggested using the “summon” mode to have the car come to us... Read more

Crash

Incident date: Jul 4, 2026

I live in [XXX]. On the way to [XXX], out of no where the car stopped accelerating. Was in eco mode at the time and dropped completely while trying to accelerate in the middle of the road. Pulled over completely turned off the car checked the engine nothing seemed out of the ordinary. Ran the diagno... Read more

Incident date: Jul 4, 2026

SC368 CROSS OVER FUEL PIPE recall incomplete by kia of des moines

Incident date: Jul 4, 2026

There is a major fuel line leak just before the high pressure fuel pump. It appears that the fuel line aggressively rubbed against an A/C line component (looks like a muffler/canister). This rubbing created a huge hole in the high pressure fuel line, causing diesel to spray everywhere on the driver ... Read more

Incident date: Jun 1, 2026

I have been in my vehicle at a red light and my van will not start. The start button is pressed and the vehicle makes clicking noises or won’t make a sound at all. Finally it starts

Incident date: Jun 1, 2026

I have been in my vehicle at a red light and my van will not start. The start button is pressed and the vehicle makes clicking noises or won’t make a sound at all. Finally it starts

Incident date: Jun 1, 2026

When attempting to accelerate (gently) on the highway, the vehicle hunted for gears and shook violently and have zero acceleration. A wrench flashed on the screen of car. Felt like it went to neutral as engine rpm's increased rapidly accompanied with a loud thunk. Thankfully we were in a safe spot ... Read more

Incident date: May 1, 2026

many times when I am using pro pilot assist it does not brake to point when it is inches of crashing into car in front, I manually have to apply brakes. in addition while being in full automatic mode (hands free mode) it turns off lane keeping assist completely where if the driver was not Able to ma... Read more

Incident date: Jun 5, 2026

2025 Palisade Night edition black grill and associated trim will peel and flake paint off from normal wear and tear including hand washing. I am on my third grill and trim which was installed damaged. This is like no vehicle I have ever owned in terms of the sensitive nature of the front grill compo... Read more

Incident date: May 26, 2026

[XXX] [XXX] Fax: [XXX] [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

Incident date: Jun 2, 2026

The vehicle experiences a recurring electronic and sensor failure where critical advanced safety systems completely shut down while driving. The dashboard displays active failures for the Front Collision Detection System, Automatic Headlights, and Lane Keeping Assistance. These sudden defects direct... Read more

Incident date: Jun 2, 2026

Incident date: Jun 1, 2026

The contact owns a 2020 Ford Escape. The contact received notification of NHTSA Campaign Number: 25V467000 (Fuel System, Gasoline); however, the part to do the recall repair was not yet available. The contact stated while driving at various speeds, the vehicle shuddered. The check engine warning lig... Read more

Incident date: May 20, 2026

The contact owns a 2021 Jeep Cherokee. The contact stated that while driving approximately 45 MPH, the vehicle lost motive power with the 4-wheel drive warning light illuminated. The vehicle was able to restart. The vehicle was taken to an independent mechanic, where it was diagnosed that the transf... Read more

Incident date: Apr 6, 2026

Rear passenger seatbelt warning beeps continuously when seat is occupied and belt is latched.

Incident date: May 4, 2026

While driving underneath an overpass immediately, followed by an intersection, as I accelerate through the stop lit intersection in the early hours of the morning, my Rogue’s forward collision, alert flashes yellow, and white, and I lose acceleration. It feels as if the car shifted to neutral and ... Read more

Incident date: Apr 30, 2026

During the day after driving in rain in a 2023 Rav 4 LE AWD with 19000 miles car turned off. I was parked with it idling and with no warning stalled. I turned on multiple times and it kept stalling out. Finally a message appeared on dash "power steering low". After inspecting under hood and seeing a... Read more

Incident date: Apr 15, 2026

The cover of this car seat has only been cared for per the manufacturer instructions, and the warning labels on the sides are peeling, creating a choking hazard. Clek has issued a recall for Liing before for this specific issue, but is saying that my Liing is not included despite being manufactured ... Read more

Incident date: Feb 15, 2026

When decelerating/braking there is a knocking in the rear of the car. It has gotten progressively worse. Had the dealership check it out but found nothing wrong. They didn't drive the car.

Incident date: Feb 13, 2026

I have had shifting issues with the transmission since 2 months into having this vehicle I have been reporting it to the dealership who has told me consistently that jerking grinding and loud noises are totally normal then the recall came out for these specific issues in the 2017 Silverados though m... Read more

Showing 50 of 268 complaints.

NHTSA Safety Ratings, 2023 TOYOTA RAV4

2023 Toyota RAV4 SUV AWD

Category	Rating
Overall Rating	5 / 5 ★★★★★
Frontal Crash	4 / 5 ★★★★☆
Frontal Crash, Driver	4 / 5 ★★★★☆
Frontal Crash, Passenger	5 / 5 ★★★★★
Side Crash	5 / 5 ★★★★★
Side Crash, Driver	5 / 5 ★★★★★
Side Crash, Passenger	5 / 5 ★★★★★
Rollover	4 / 5 ★★★★☆
Rollover Risk	15.5%

Safety Technology

Feature	Status
Electronic Stability Control	Standard
Forward Collision Warning	Standard
Lane Departure Warning	Standard

Source: NHTSA 5-Star Safety Ratings Program. Ratings are based on crash tests conducted by the National Highway Traffic Safety Administration.

EPA Fuel Economy, 2023 TOYOTA RAV4

Trim / Engine	City MPG	Highway MPG	Combined MPG	Fuel Type	Annual Fuel Cost
2.5L 4-cyl, Automatic (S8) (Front-Wheel Drive)	27.0	35.0	30.0	Regular	$2,050
2.5L 4-cyl, Automatic (S8) (Front-Wheel Drive)	27.0	34.0	30.0	Regular	$2,050

CO2 Emissions: 296.0 g/mile (Small Sport Utility Vehicle 2WD)

Source: U.S. Environmental Protection Agency (EPA). Actual fuel economy may vary based on driving conditions.

Technical Service Bulletins, 2023 TOYOTA RAV4

48 manufacturer communications from 30 unique bulletins. TSBs describe known problems and recommended fixes from the manufacturer.

Most Affected Components

Component	Bulletins
116340 ELECTRICAL SYSTEM:IGNITION:ANTI-THEFT:IMMOBILIZER/PROXIMITY:KEY/SENDER	12
060000 ENGINE AND ENGINE COOLING	6
110000 ELECTRICAL SYSTEM	5
980000 UNKNOWN OR OTHER	3
280000 BACK OVER PREVENTION	2
350000 EQUIPMENT	2
280100 BACK OVER PREVENTION:SOFTWARE	2
353400 EQUIPMENT:ELECTRICAL:RADIO/TAPE DECK/CD ETC.	1

980000 UNKNOWN OR OTHER

TT: Engine Oil Leak between the Lower Oil Pan and Crank Case

063110 ENGINE AND ENGINE COOLING:EXHAUST SYSTEM:EMISSION CONTROL:CRANKCASE (PCV)

TT: Engine Oil Leak between the Lower Oil Pan and Crank Case

116340 ELECTRICAL SYSTEM:IGNITION:ANTI-THEFT:IMMOBILIZER/PROXIMITY:KEY/SENDER

The table describes the phases currently planned for the Second Key Delivery Program and the estimated timing of announcement. This table will be updated during each phase launch and as more details become available.

116340 ELECTRICAL SYSTEM:IGNITION:ANTI-THEFT:IMMOBILIZER/PROXIMITY:KEY/SENDER

DP: The subject vehicles were delivered with only one (1) Smart Key on select models since October 2022 due to a global semiconductor shortage impacting certain microchips. The affected vehicles were delivered with one (1) Smart Key and a s

110000 ELECTRICAL SYSTEM

TSB: The Immobilizer and Smart Key Reset is a feature that allows the registration of new keys when all master keys are lost. Once the system is reset, all previously registered keys will be erased and can never be reused. Another feature,

060000 ENGINE AND ENGINE COOLING

This is to advise of various price adjustments that will affect Toyota Genuine Motor Oil and Long Life Coolant, effective March 1, 2024. These products are ordered through the Toyota Complete Maintenance Care (TCMC) website.

061500 ENGINE AND ENGINE COOLING:ENGINE:OIL/LUBRICATION

980000 UNKNOWN OR OTHER

060000 ENGINE AND ENGINE COOLING

TSB: Some 2021 ? 2022 model year Avalon, 2018 ? 2024 Camry, and 2019 ? 2024 RAV4 vehicles with A25A-FKS engines may have a MIL ON condition with one or more of the following Diagnostic Trouble Codes (DTCs) upon cold soak start up with engin

270000 LANE DEPARTURE

TSB: Some 2018 ? 2024 model year Toyota vehicles equipped with an A25A-FKS, A25A-FXS, M20A-FKS, or M20A-FXS engine may exhibit one or more of the following conditions: ?Milky/discolored engine oil. ?An ?Oil Pressure Low? warning message

110000 ELECTRICAL SYSTEM

062000 ENGINE AND ENGINE COOLING:COOLING SYSTEM

030000 SERVICE BRAKES, HYDRAULIC

116340 ELECTRICAL SYSTEM:IGNITION:ANTI-THEFT:IMMOBILIZER/PROXIMITY:KEY/SENDER

TI: TECHNICAL INSTRUCTIONS FOR 23TJ01 Second Key Delivery Program Multiple Models and Model Years

116340 ELECTRICAL SYSTEM:IGNITION:ANTI-THEFT:IMMOBILIZER/PROXIMITY:KEY/SENDER

RL: The supply of Smart Keys available for Toyota vehicles has been temporarily limited to one (1) on select models since October 2022 due to global semiconductor shortages impacting certain microchips. Affected vehicles have been delivered

110000 ELECTRICAL SYSTEM

116340 ELECTRICAL SYSTEM:IGNITION:ANTI-THEFT:IMMOBILIZER/PROXIMITY:KEY/SENDER

110000 ELECTRICAL SYSTEM

116340 ELECTRICAL SYSTEM:IGNITION:ANTI-THEFT:IMMOBILIZER/PROXIMITY:KEY/SENDER

TI: TECHNICAL INSTRUCTIONS FOR 23TJ01 Second Key Delivery Program Multiple Models and Model Years

116340 ELECTRICAL SYSTEM:IGNITION:ANTI-THEFT:IMMOBILIZER/PROXIMITY:KEY/SENDER

TI: TECHNICAL INSTRUCTIONS FOR 23TJ01 Second Key Delivery Program Multiple Models and Model Years

116340 ELECTRICAL SYSTEM:IGNITION:ANTI-THEFT:IMMOBILIZER/PROXIMITY:KEY/SENDER

138500 VISIBILITY:DEFROSTER/DEFOGGER/HVAC SYSTEM:REFRIGERANT HOSES AND FITTINGS

TSB: The air conditioning dye injection tool kit has been developed to aid in identifying the location of air conditioning refrigerant leaks. Follow the procedures outlined in this service bulletin to aid in locating, inspecting, and repair

980000 UNKNOWN OR OTHER

TT: A very small percentage of customers experience operational difficulties with some telematics features which they cannot resolve on their own. These resources, in conjunction with the Repair Manual, are for dealership personnel to assis

350000 EQUIPMENT

TSB: Replacement certification labels (the vinyl label installed on the driver door or door post) and VIN plates (the metal plate riveted to dashboard) (see Figure 1) for most 1979 ? 2023 model year vehicles may be available provided the re

180000 VEHICLE SPEED CONTROL

140000 AIR BAGS

346000 COMMUNICATION:MANUFACTURER TELEMATICS

060000 ENGINE AND ENGINE COOLING

TT: Some 2021 - 2023 Highlander HV, RAV4 HV and Sienna HV vehicles equipped with Rear Motor Generator, MGR (Q610), may duplicate an abnormal noise (Drone, Growl, Humming, and/or other) from the MGR at various vehicle speeds and normal drive

280000 BACK OVER PREVENTION

280100 BACK OVER PREVENTION:SOFTWARE

TT: This issue is currently under investigation. Please create TAS case and attach a store all health check. Please contact TAS for further instructions. If it is a weekend or a holiday, continue with diagnosis and repair. Please save all p

200000 WHEELS

TSB: Some 2023 ? 2024 model year Toyota vehicles use hub bolts in place of studs/nuts to fasten the wheels to the vehicle. If non-compatible wheels or hub bolts/nuts are installed, there is increased risk that the wheel(s) could come off re

280100 BACK OVER PREVENTION:SOFTWARE

TSB: Some 2023 model year GR Corolla, RAV4, RAV4 Hybrid, RAV4 Prime, and Venza Hybrid vehicles with multimedia version older than 1564 may exhibit one or more of the following conditions: ?Head unit rebooting (does not affect backup camer

350000 EQUIPMENT

116340 ELECTRICAL SYSTEM:IGNITION:ANTI-THEFT:IMMOBILIZER/PROXIMITY:KEY/SENDER

TI: TECHNICAL INSTRUCTIONS FOR 23TJ01 Second Key Delivery Program

070000 FUEL SYSTEM, GASOLINE

TSB: Some 2020 ? 2023 model year Highlander Hybrid and 2021 ? 2023 model year RAV4 Hybrid, RAV4 Prime, Sienna Hybrid, and Venza Hybrid vehicles may exhibit a MIL ON condition with one or both of the following Diagnostic Trouble Codes (DTCs)

063100 ENGINE AND ENGINE COOLING:EXHAUST SYSTEM:EMISSION CONTROL

353400 EQUIPMENT:ELECTRICAL:RADIO/TAPE DECK/CD ETC.

TT: When setting up the Toyota Audio Multimedia (21MM) user profile, if the QR code is not working please use the following recommendations.

110000 ELECTRICAL SYSTEM

TT: Some 2022-2024 MY vehicles equipped with the A25A engine may exhibit a leak from the engine water pump, and/or MIL On condition accompanied by DTC(s): ?P26CA14 Engine Coolant Pump Circuit Short to Ground or Open ?P26CA31 Engine Cool

060000 ENGINE AND ENGINE COOLING

061400 ENGINE AND ENGINE COOLING:ENGINE:HARD PARTS INTERNAL/MECHANICAL

TT: Some Model Year 2018-2023 vehicles equipped with A25A-FKS/FXS or M20A-FKS/FXS engines may display the following message ?Engine Maintenance Required Visit Your Dealer? on the combination meter

280000 BACK OVER PREVENTION

060000 ENGINE AND ENGINE COOLING

TT: Some 2021 to 2023 MY vehicles equipped Rear Motor Generator, MGR (Q610) may experience an oil leak concern. This issue is currently under investigation

100000 POWER TRAIN

TT: Some 2019- 2023 RAV4 HV vehicles may duplicate an abnormal noise (Growl, Humming and/or other) from the Hybrid T/A and/or MGR at various vehicle speeds and normal drive conditions

030000 BRAKES (PWS)

TSB: Some 2019 ? 2023 model year RAV4 and RAV4 Hybrid vehicles may exhibit a squeal/squeak noise from the front brakes with light to moderate braking. Follow the Repair Procedure in this bulletin to address this condition

NHTSA Safety Investigations, TOYOTA RAV4

Investigations opened by NHTSA into potential safety defects. These are separate from recalls and may or may not result in a recall.

PE, Closed , Model Year: 2013

Battery Hold Down Bracket Thermal Events

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 ope... ning, 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.Read more

PE, Closed , Model Year: 2006

Rear Suspension Arm Assembly Failure

In a letter dated August 1, 2012 Toyota Motor Engineering & Manufacturing North America, Inc. (Toyota) submitted a Defect Information Report (NHTSA Recall No. 12V-373) to the NHTSA identifying a safety defect regarding possible separation of the Rear Suspension Arm No. 1 Assembly (arm) at the thread... ed portion (shaft and turn buckle) of the component in MY 2006 through MY 2011 Toyota RAV4 vehicles built from October 2005 through September 2010 and in MY 2010 Lexus HS250h vehicles manufactured from July 2009 through August 2010.According to Toyota, if the adjustment nuts for the rear wheel alignment are improperly tightened when alignment is performed in service, backlash may develop at the threaded portion of the arm, followed by rust formation.The threads may then wear causing the arm to separate, which may result in a loss of vehicle control.In analysis of both Vehicle Owner Questionnaire (VOQ) data submitted to the Office of Defects Investigation (ODI) and consumer complaint data submitted to Toyota, ODI identified 131 non-duplicative reports alleging failure of the subject rear suspension arm (Note:some of the complaints and related service records refer to the arm as a rear tie rod).Six of the complainants allege the failure resulted in some loss of vehicle control.For purposes of this analysis, loss of control events involve alleged complete or partial departure from the intended lane of travel.An additional four complaints reported difficulty maintaining control of the vehicle when the arm failed.Recalled vehicles will be inspected for proper torque of the adjustment nuts and replaced as necessary.In addition, Toyota will take several actions to reduce the potential for improper torque in future alignment procedures.This includes:(1) providing proper tightening sequence and torque specification information to two major wheel alignment equipment manufacturers, who would disseminate the information to alignment shops using their equipment; (2) installation of a clip on each arm with an instructional label showing proper tightening sequence and torque specification (the clip must be removed to perform a wheel alignment); (3) installation of additional labels on the front and back vertical surfaces of the Rear Suspension Arm No. 2 assemblies; and (4) providing an instruction booklet to owners to place in the glove box.This investigation is closed.Read more

TOYOTA RAV4 - All Years Overview

Complete safety history for the TOYOTA RAV4 across all model years (1996, 2025).

149 Total Recalls

12,221 Total Complaints

2 Investigations

1,075 Reported Crashes

359 Reported Fires

11 Reported Deaths

TOYOTA RAV4 - Year by Year

Compare recalls and complaints across model years. Click any year to see full details.

Year	Recalls	Complaints
2025	3	126	View
2024	3	265	View
2023 (current)	3	268
2022	1	225	View
2021	1	522	View
2020	6	805	View
2019	7	1,183	View
2018	3	443	View
2017	3	416	View
2016	3	298	View
2015	4	400	View
2014	4	279	View
2013	2	332	View
2012	5	357	View
2011	11	403	View
2010	14	498	View
2009	15	397	View
2008	14	708	View
2007	14	1,241	View
2006	11	880	View
2005	5	168	View
2004	2	183	View
2003	0	392	View
2002	0	682	View
2001	0	418	View
2000	3	34	View
1999	5	75	View
1998	5	92	View
1997	1	61	View
1996	1	54	View
1995	0	1	View
1994	0	4	View

Other TOYOTA Models

Model	Recalls	Complaints
TUNDRA	787	9,074	View
HIGHLANDER	677	6,756	View
CROWN	548	141	View
TACOMA	406	10,562	View
VENZA	404	969	View
GRAND HIGHLANDER	388	332	View
PRIUS	365	15,456	View
HIGHLANDER HYBRID	355	1,103	View

Vehicle Safety

Consumer Safety

Infrastructure

Public Health

2023 TOYOTA RAV4

Complaint Statistics

Top Reported Components

NHTSA Safety Ratings, 2023 TOYOTA RAV4

Safety Technology

EPA Fuel Economy, 2023 TOYOTA RAV4

Technical Service Bulletins, 2023 TOYOTA RAV4

Most Affected Components

NHTSA Safety Investigations, TOYOTA RAV4

TOYOTA RAV4 - All Years Overview

TOYOTA RAV4 - Year by Year

Other TOYOTA Models