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2004 Toyota Prius

Owner reports · Recalls · Investigations

More warning signs than most Prius years

Owner complaints for the 2004 Toyota Prius are substantially higher than the model-year median of 164.

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When problems were reported

Mileage at the reported incident

503 reports with mileage · 107 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.

  • Exterior Lighting. Review the 184 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Electrical System. Review the 177 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Engine And Engine Cooling. Review the 89 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →

NHTSA owner reports · September 18, 2026 snapshot.

38 crash reports2 fire reports21 injury reports

Electrical System complaints

177 reports
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17 miles · May 26, 2005
Electrical System

OMG, OMG ITS SO FRESH IN MY MIND!. I WAS TERRIFIED. MY DAUGHTER(OLDEST) WAS IN A TERRIBLE CAR ACCIDENT AND WAS TAKEN TO THE HOSPITAL(MARY WASHINGTON IN VA.) I WAS AT WORK AND GOT THE HORRIFIC CALL ABOUT 1745HRS (RUSH HOUR). I JUMPED IN MY CAR(2004-PRIUS) I I CAN'T TELL YOU HOW I FELT. AS I ENTERED THE HOV LANES FROM DC TO VA, M…

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OMG, OMG ITS SO FRESH IN MY MIND!. I WAS TERRIFIED. MY DAUGHTER(OLDEST) WAS IN A TERRIBLE CAR ACCIDENT AND WAS TAKEN TO THE HOSPITAL(MARY WASHINGTON IN VA.) I WAS AT WORK AND GOT THE HORRIFIC CALL ABOUT 1745HRS (RUSH HOUR). I JUMPED IN MY CAR(2004-PRIUS) I I CAN'T TELL YOU HOW I FELT. AS I ENTERED THE HOV LANES FROM DC TO VA, MY CAR STARTED PAUSING..I'VE FELT THIS BEFORE, SO I HIT THE INFO BUTTON AND SEE MY BATTERY TOOK OVER AND IS ON 4 LINES! I THEN SEE THE ALERT LIGHTS ILLUMINATE ON MY DASH! THIS CAN'T BE HAPPENING?, NOT NOW!..I IMMEDIATELY HIT MY HORN AND AVOID GETTING SLAMMED INTO BY VEHICLES BEHIND ME. I SLOWLY CREEP ON MY LAST BATTERY LINE ONTO THE RIGHTHAND SHOULDER. MY PRIUS DIED. I CALLED TOYOTAS' (RAP>ROADSIDE ASSISTANCE PROGRAM) AND A TOW TRUCK WAS SENT. I BROKE DOWN IN DC AND (TOYOTAS' RAP) ONLY TAKES ME 50MILES FROM THE BREAKDOWN. I LIVE 62 MILES AWAY! THIS IS NOT ACCEPTABLE! I WAS TOWED TO SPRINGFIELD TOYOTAN AND IT WAS CLOSED! (IT IS NOW 2130HRS! AND I'M STILL NOT AT THE HOSPITAL AND I'M IN TEARS!) THE TOW TRUCK DRIVER WAS NICE ENOUGH TO TELL ME TO CALL MY INSURANCE CO. I DID AND THEY SENT ANOTHER TOW TRUCK TO PICK ME UP. IT IS NOW 2230HRS! I STILL DON'T KNOW THE STATUS OF MY DAUGHTER! THE TOW TRUCK BRINGS ME TO FREDERICKSBURG BUT TO A NISSAN DEALERSHIP, IT SEEMS THE ADDRESS WAS WRONG. WE FIGURED OUT THAT TOYOTA POHANKA WAS DOWN THE STREET AND THE TOW TRUCK DRIVER WAS CONSIDERATE ENOUGH TO BRING ME THERE. I HAD TO DROP OFF THE VEHICLE AND LUCKY I HAD SOMEONE PICK ME UP TO BRING ME HOME. TOYOTA POHANKA OF FREDERICKSBURG CALLED ME THE NEXT DAY AND SAID THEY FOUND ERROR CODE P3191 REFERRED TO THE TSB AND REPROGRAMMED THE ENGINE ECM PER INSTRUCTIONS.

NHTSA ODI #10122175

9,137 miles · May 25, 2005
Electrical System

PURCHASED A 2004 TOYOTA PRIUS ON MARCH 2, 2004. ON MAY 24, 2004 THE CAR STOPPED WHILE I WAS DRIVING IT. I COULD NOT RESTART IT FOR APPROXIMATELY 15 MINUTES. I SAT IN THE MIDDLE OF THE STREET DURING THAT TIME. THE DEALER SAID THEY HAD NEVER HEARD OF THIS HAPPENING. OM JUNE 16, 2004 THE CAR STOPPED RUNNING WHILE I WAS AT AN I…

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PURCHASED A 2004 TOYOTA PRIUS ON MARCH 2, 2004. ON MAY 24, 2004 THE CAR STOPPED WHILE I WAS DRIVING IT. I COULD NOT RESTART IT FOR APPROXIMATELY 15 MINUTES. I SAT IN THE MIDDLE OF THE STREET DURING THAT TIME. THE DEALER SAID THEY HAD NEVER HEARD OF THIS HAPPENING. OM JUNE 16, 2004 THE CAR STOPPED RUNNING WHILE I WAS AT AN INTERSECTION. I HAD TO WAIT APPROXIMATELY 15 MINUTES BEFORE IT WOULD START. THE DEALER SAID THEY DIDN'T KNOW ANYTHING ABOUT THIS. ON JUNE 21, 2004 THE CAR COMPUTERS WERE TESTED ON A RECALL AND FOUND TO BE OUT OF SYNC. THEY WERE ADJUSTED AND I WAS TOLD THAT WOULD TAKE CARE OF MY PROBLEM. IN CONTINUED TO HAVE PROBLEMS WITH THE CAR NOT STARTING. ON OCT. 6, 2004 I WAS GIVEN A NEW CAR REMOTE CONTROL TO FIX THE PROBLEM. I CONTINUED TO HAVE PROBLEMS. ON DECEMBER 6, 2004 THE CAR COMPLETELY FAILED. I WAS UNABLE TO START OR TURN OFF THE CAR. AFTER 20 MINUTES IT STARTED AND I WAS ABLE TO LEAVE IT WITH THE DEALER. THE MULTI DISPLAY UNIT WAS REPLACED. THE CAR CONTINUED TO STOP INTERMITTENTLY;. ON JANUARY 19, 2005 THE CAR FAILED TO START. A NEW SMALL BATTERY WAS INSTALLED. ON MARCH 29, 2005 THE BRAKES LOCKED UP. THE ABS ACTUATOR WAS REPLACED. ON MAY 21, 2005 THE CAR FAILED TO START. IT IS PRESENTLY AT THE DEALER.

NHTSA ODI #10122093

20,000 miles · May 23, 2005
Electrical System

A COUPLE OF MONTHS AGO WHILE DRIVING MY 2004 TOYOTA PRIUS IT LOST POWER AND ALL SORTS OF WARNING LIGHTS CAME ON. I TOOK IT STRAIGHT TO THE DEALER. AT THAT TIME THEY TOLD ME IT LOSS IT'S COMPUTER PROGRAM AND WENT INTO THE "LIMP HOME" MODE. THEY REPROGAMED IT AND IT RAN FINE. ON 5/8/05 AFTER A SHORT DRIVE I STOPED AND WHEN I T…

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A COUPLE OF MONTHS AGO WHILE DRIVING MY 2004 TOYOTA PRIUS IT LOST POWER AND ALL SORTS OF WARNING LIGHTS CAME ON. I TOOK IT STRAIGHT TO THE DEALER. AT THAT TIME THEY TOLD ME IT LOSS IT'S COMPUTER PROGRAM AND WENT INTO THE "LIMP HOME" MODE. THEY REPROGAMED IT AND IT RAN FINE. ON 5/8/05 AFTER A SHORT DRIVE I STOPED AND WHEN I TRIED TO RESTART IT, IT WOULD NOT START. ALL I COULD GET WAS A LOT OF WARNING LIGHTS AND A WIRLING SOUND. I CALLED AAA TO HAVE IT TOWED TO THE DEALER. JUST AS THE TOW TRUCH ARRIVED I TRIED TO START IT AGAIN AND IT STARTED LIKE NORMAL. I DROVE IT TO THE DEAL AND EXPLAINED THE PROBLEM TO THEM. THEY COULD NOT FIND ANY TROUBLE CODES OR PROBLEM WITH THE CAR. IT HAS RAN FINE SENCE THEN. BUT I NOW WORRY WHEN IT WILL ACT UP AGAIN.

NHTSA ODI #10121879

12,500 miles · May 23, 2005
Electrical System

WHILE DRIVING AT APPROXIMATELY 35 MPH THE VEHICLE COMPLETELY SHUT DOWN. THE VEHICLE WAS HYBRID. THE OWNER HAD THE VEHICLE TOWED TO THE DEALER, AND WAS INFORMED THAT THE BATTERY WAS CHARGED, AND THERE WAS NOTHING WRONG WITH THE VEHICLE. *AK THERE WERE A SERIES OF THESE EVENTS. THE VEHICLE ALSO STALLED WHILE IN MOTION. TH…

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WHILE DRIVING AT APPROXIMATELY 35 MPH THE VEHICLE COMPLETELY SHUT DOWN. THE VEHICLE WAS HYBRID. THE OWNER HAD THE VEHICLE TOWED TO THE DEALER, AND WAS INFORMED THAT THE BATTERY WAS CHARGED, AND THERE WAS NOTHING WRONG WITH THE VEHICLE. *AK THERE WERE A SERIES OF THESE EVENTS. THE VEHICLE ALSO STALLED WHILE IN MOTION. THE CONSUMER WAS INFORMED THAT THE CHARGING SYSTEM WAS TESTED AND NOTHING WAS WRONG WITH THE VEHICLE. *SC *JB

NHTSA ODI #10119116

11,300 miles · May 20, 2005
Electrical System

MY WIFE'S 2004 TOYOTA PRIUS LOST POWER 100 MILES AWAY FROM HOME. SHE WAS WITH OUR 3 MONTH OLD BABY AND FORTUNATELY WAS NOT REAR ENDED OR INVOLOVED IN AN ACCIDENT.

NHTSA ODI #10121728

6,800 miles · May 18, 2005
Electrical System

DRIVING MY 2004 TOYOTA PRIUS HOME FROM WORK, THE CAR SUDDENLY LOST POWER A FEW MILES FROM MY HOME ON A BUSY THOROUGHFARE. I DRIFTED TO THE SIDE OF THE ROAD. ALL WARNING LIGHTS ON THE DASH WERE ON. I TURNED OFF THE CAR AND RESTARTED IT. IT WENT A FEW SECONDS BEFORE DYING AGAIN. THIS CONTINUED SEVERAL TIMES UNTIL I MADE IT HO…

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DRIVING MY 2004 TOYOTA PRIUS HOME FROM WORK, THE CAR SUDDENLY LOST POWER A FEW MILES FROM MY HOME ON A BUSY THOROUGHFARE. I DRIFTED TO THE SIDE OF THE ROAD. ALL WARNING LIGHTS ON THE DASH WERE ON. I TURNED OFF THE CAR AND RESTARTED IT. IT WENT A FEW SECONDS BEFORE DYING AGAIN. THIS CONTINUED SEVERAL TIMES UNTIL I MADE IT HOME. THE INCIDENT CAUSED OTHER CARS TO HAVE TO SLOW DOWN, HONK AND MOVE AROUND ME. I WAS VERY SCARED. IT WAS LATE AT NIGHT. I CALLED MY HUSBAND TO COME HELP ME BUT HE WAS NOT HOME. THE NEXT DAY THE CAR STARTED AND I TOOK IT TO THE DEALERSHIP. THEY COULD FIND NOTHING WRONG, AND SAID THEY "RESET THE ENGINE/BATTERY RATIO" SO THE CAR WOULD RELY MORE ON GAS THAN ELECTRICITY , AND THAT I WOULD EXPERIENCE A SLIGHT DECREASE IN MY ENGINE EFFICIENCY. I LATER COMPLAINED TO THE SERVICE MANAGER, THAT MY PRIUS HAS HAD NUMEROUS ELECTRICAL PROBLEMS SINCE I PURCHASED IT IN AUGUST OF2005. TWICE IT WOULD NOT START IN THE MORNING AND I HAD TO HAVE IT TOWED. HE ALSO TOLD ME THAT WHAT THE SERVICE PERSON TOLD ME WAS INCORRECT, THAT THERE WAS NO WAY THEY CAN "ADJUST" THE ENGINE/BATTERY RATIO. HE GAVE NO EXPLANATION FOR MY PROBLEMS AND SAID "NO ONE ELSE" HAS HAD ANY PROBLEMS WITH THEIR CARS. I WANT TO RETURN THE CAR FOR A NEW ONE, BUT HE SAYS HE FEELS "CONFIDENT" TOYOTA WILL CORRECT ANY PROBLEMS I AM HAVING. I AM AFRAID TO DRIVE THE CAR IN CASE THIS HAPPENS AGAIN. TOYOTA HAS DONE NOTHING SINCE I HAVE COMPLAINED. I FEEL THEY OWE ME A NEW CAR WHILE THEY FIGURE THIS OUT.

NHTSA ODI #10121310

8,700 miles · May 18, 2005
Electrical System

AN ARTICLE IN YESTERDAY'S L.A. TIMES (5/17) DETAILED A PROBLEM WITH THE 2004/05 TOYOTA PRIUS, WHERE IT MENTIONED THAT 13 PRIUS OWNERS REPORTED THAT THEIR VEHICLES STALLED SUDDENLY, OFTEN AT HIGH SPEEDS. ON APRIL 12, 2005, THE EXACT SAME THING HAPPENED TO ME. WHILE SLOWING FROM 65 M.P.H. ON I-10 IN WEST L.A. ONTO THE I-405 IN…

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AN ARTICLE IN YESTERDAY'S L.A. TIMES (5/17) DETAILED A PROBLEM WITH THE 2004/05 TOYOTA PRIUS, WHERE IT MENTIONED THAT 13 PRIUS OWNERS REPORTED THAT THEIR VEHICLES STALLED SUDDENLY, OFTEN AT HIGH SPEEDS. ON APRIL 12, 2005, THE EXACT SAME THING HAPPENED TO ME. WHILE SLOWING FROM 65 M.P.H. ON I-10 IN WEST L.A. ONTO THE I-405 INTERCHANGE, EASILY ONE OF THE MOST CONGESTED HIGHWAY INTERCHANGES IN THE COUNTRY, MY PRIUS STALLED AND I WAS EXTREMELY FORTUNATE TO MAKE IT TO THE END OF THE INTERCHANGE WHERE THE SHOULDER BEGAN. HAD IT OCCURED A MERE TWO MINUTES LATER, I WOULD HAVE BEEN IN THE FAST LANE OF THE 405, TRIGGERING A POTENTIAL DISASTER AND CERTAIN SIGALERT, AS IT OCCURED AT 8:15 A.M.--RUSH HOUR. MY CAR HAD APPROXIMATELY 8,700 MILES AND WAS PURCHASED NEW IN AUGUST, 2004. I HAD IT TOWED TO TOYOTA OF SANTA MONICA WHERE I PURCHASED THE CAR, AND WAS DISMAYED AT THEIR NONCHALANCE. A BRAND NEW CAR SHOULD NOT BREAK DOWN FOR NO REASON, AND IT COULD'VE RESULTED IN A SERIOUS ACCIDENT. MORE TRO UBLING, THE TOYOTA SERVICE DEPARTMENT'S TECHNICAL ASSESSMENT OF THE PROBLEM WAS THAT IT WAS A "COMPUTER GLITCH," AND THAT THEIR REPAIR SERVICE WAS TO "REPROGRAM THE COMPUTER." I HAVE BEEN A LOYAL AND VOCAL SUPPORTER OF THIS HYBRID VEHICLE, PLEASED IN EVERY WAY WITH THE PERFORMANCE OF THE CAR. NOW WHEN PEOPLE ASK, I GIVE THEM MUCH THE SAME ANSWER, BUT VERBALLY INSERT AN ASTERISK AND TELL THEM ABOUT THE TIME IT BROKE DOWN WITHOUT WARNING, AND HOW I HAVE NO GUARANTEE IT WON'T HAPPEN AGAIN. YOU CAN COUNT ME AS THE 14TH OWNER TO REPORT THIS IDENTICAL PROBLEM. AND YOU CAN BE SURE THAT WE ARE ONLY A PERCENTAGE OF THE EVER-GROWING PRIUS OWNERS WHO HAVE EXPERIENCED THIS. I HOPE YOUR FINDINGS AND THE ARTICLE WILL MAKE THEIR WAY TO TOYOTA'S RECEPTIVE AND RESPONSIVE EARS. THANKS.

NHTSA ODI #10121292

27,000 miles · May 18, 2005
Electrical System

THE CAR STOPPED IN THE MIDDLE OF THE ROAD JUST AFTER ALL THE WARNING LIGHTS CAME ON

NHTSA ODI #10121291

20,400 miles · May 17, 2005
Electrical SystemEngine And Engine Cooling

5/6/05 MY 2004 PRIUS WITH 20,400 MILES WITHOUT WARNING LOSS ALL POWER AND SHUT DOWN WHILE DRIVING HAZARD LIGHT CAME ON WARNING TO TAKE TO TOYOTA DEALER. THE VEHICLE WOULD NOT START. THE BATTERY METER LEVEL WAS COMPLETELY DEAD. THE VEHICLE HAD TO BE TOWED TO MAITA TOYOTA 2500 AUBURN BLVD, SACRAMENTO, CA 95821, 916 481-5353 FO…

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5/6/05 MY 2004 PRIUS WITH 20,400 MILES WITHOUT WARNING LOSS ALL POWER AND SHUT DOWN WHILE DRIVING HAZARD LIGHT CAME ON WARNING TO TAKE TO TOYOTA DEALER. THE VEHICLE WOULD NOT START. THE BATTERY METER LEVEL WAS COMPLETELY DEAD. THE VEHICLE HAD TO BE TOWED TO MAITA TOYOTA 2500 AUBURN BLVD, SACRAMENTO, CA 95821, 916 481-5353 FOR REPAIR. THE WORK ORDER STATED THE CAUSE WAS THE ECU WHICH WAS REPROGRAMED WHICH CLEARED STORED CODES. CODE PULLED P3191. IS THIS A NEW FINDING IN THE PRIUS?

NHTSA ODI #10121239

2,000 miles · May 17, 2005
Electrical System

HAVE A 2004 TOYOTA PRIUS. LESS THAN 40,000 MILES ON THE CAR. WAS DRIVING ON THE FREEWAY AND IT SUDDENLY DIED FOR NO REASON. TOYOTA DEALER SAID IT WAS A COMPUTER MALFUNCTION AND COULD NOT GUARENTEE IT WOULD NOT HAPPEN AGAIN. VERY UPSET ABOUT THIS AS IT IS A NEW CAR I PAID A LOT OF MONEY FOR

NHTSA ODI #10121183

Official recalls

6

12V536000 · Engine And Engine Cooling; Hybrid Propulsion System: Inverter

Nov 14, 2012

Toyota is recalling certain model year 2004-2009 Prius vehicles manufactured August 6, 2003, through March 30, 2009 and FCHV-adv vehicles manufactured December 12, 2008, through September 13, 2011. During manufacturing, a scratch may have occurred inside of the electrically driven water pump at the coil wire. The coil wire may corrode at the scratched portion.

Consequence & remedy

Consequence: The corroded coil wire may break and the water pump could stop. The corroded coil wire could cause a short circuit between coil wires and a possible open fuse, creating a stall-like condition of the hybrid system while the vehicle is being driven. This may increase the risk of a vehicle crash.

Remedy: Toyota will notify its owners, and dealers will replace the electric water pump, free of charge. The recall began on January 17, 2013. Owners may contact their Toyota dealer or the Toyota Customer Experience Center at 1-800-331-4331.

Additional source detail variants (2)

Hybrid Propulsion System: Inverter

Toyota is recalling certain model year 2004-2009 Prius vehicles manufactured August 6, 2003, through March 30, 2009 and FCHV-adv vehicles manufactured December 12, 2008, through September 13, 2011. During manufacturing, a scratch may have occurred inside of the electrically driven water pump at the coil wire. The coil wire may corrode at the scratched portion.

Consequence: The corroded coil wire may break and the water pump could stop. The corroded coil wire could cause a short circuit between coil wires and a possible open fuse, creating a stall-like condition of the hybrid system while the vehicle is being driven. This may increase the risk of a vehicle crash.

Remedy: Toyota will notify its owners, and dealers will replace the electric water pump, free of charge. The recall began on January 17, 2013. Owners may contact their Toyota dealer or the Toyota Customer Experience Center at 1-800-331-4331.

Engine And Engine Cooling

Toyota is recalling certain model year 2004-2009 Prius vehicles manufactured August 6, 2003, through March 30, 2009 and FCHV-adv vehicles manufactured December 12, 2008, through September 13, 2011. During manufacturing, a scratch may have occurred inside of the electrically driven water pump at the coil wire. The coil wire may corrode at the scratched portion.

Consequence: The corroded coil wire may break and the water pump could stop. The corroded coil wire could cause a short circuit between coil wires and a possible open fuse, creating a stall-like condition of the hybrid system while the vehicle is being driven. This may increase the risk of a vehicle crash.

Remedy: Toyota will notify its owners, and dealers will replace the electric water pump, free of charge. The recall began on January 17, 2013. Owners may contact their Toyota dealer or the Toyota Customer Experience Center at 1-800-331-4331.

12V537000 · Steering; Steering:gear Box:shaft Sector

Nov 14, 2012

Toyota is recalling certain model year 2004-2009 Prius vehicles manufactured August 5, 2003, through March 30, 2009. The affected vehicles have a steering intermediate extension shaft assembly built with metal splines that complete the connection from the steering wheel to the steering gear. These splines may have been manufactured with an insufficient hardness.

Consequence & remedy

Consequence: Over time, the splines may wear and eventually fail resulting in a loss of steering ability, increasing the risk of a vehicle crash.

Remedy: Toyota will notify owners, and dealers will inspect the extension shaft and replace it if it is one with insufficient hardness, free of charge. The recall began during December 2012. Owners may contact their Toyota dealer or the Toyota Customer Experience Center at 1-800-331-4331.

Additional source detail variants (2)

Steering:gear Box:shaft Sector

Toyota is recalling certain model year 2004-2009 Prius vehicles manufactured August 5, 2003, through March 30, 2009. The affected vehicles have a steering intermediate extension shaft assembly built with metal splines that complete the connection from the steering wheel to the steering gear. These splines may have been manufactured with an insufficient hardness.

Consequence: Over time, the splines may wear and eventually fail resulting in a loss of steering ability, increasing the risk of a vehicle crash.

Remedy: Toyota will notify owners, and dealers will inspect the extension shaft and replace it if it is one with insufficient hardness, free of charge. The recall began during December 2012. Owners may contact their Toyota dealer or the Toyota Customer Experience Center at 1-800-331-4331.

Steering

Toyota is recalling certain model year 2004-2009 Prius vehicles manufactured August 5, 2003, through March 30, 2009. The affected vehicles have a steering intermediate extension shaft assembly built with metal splines that complete the connection from the steering wheel to the steering gear. These splines may have been manufactured with an insufficient hardness.

Consequence: Over time, the splines may wear and eventually fail resulting in a loss of steering ability, increasing the risk of a vehicle crash.

Remedy: Toyota will notify owners, and dealers will inspect the extension shaft and replace it if it is one with insufficient hardness, free of charge. The recall began during December 2012. Owners may contact their Toyota dealer or the Toyota Customer Experience Center at 1-800-331-4331.

09V388000 · Vehicle Speed Control:accelerator Pedal

Oct 5, 2009

TOYOTA IS RECALLING CERTAIN MODEL YEAR 2004-2010 PASSENGER VEHICLES. THE ACCELERATOR PEDAL CAN GET STUCK IN THE WIDE OPEN POSITION DUE TO ITS BEING TRAPPED BY AN UNSECURED OR INCOMPATIBLE DRIVER'S FLOOR MAT.

Consequence & remedy

Consequence: A STUCK OPEN ACCELERATOR PEDAL MAY RESULT IN VERY HIGH VEHICLE SPEEDS AND MAKE IT DIFFICULT TO STOP THE VEHICLE, WHICH COULD CAUSE A CRASH, SERIOUS INJURY OR DEATH.

Remedy: TOYOTA FILED AN AMENDED DEFECT REPORT ON NOVEMBER 25, 2009, STATING THAT DEALERS WILL MODIFY THE ACCELERATOR PEDAL AND, ON CERTAIN VEHICLES, ALTER THE SHAPE OF THE FLOOR SURFACE UNDER THE PEDAL. THESE CHANGES ADDRESS THE RISK OF PEDAL ENTRAPMENT DUE TO INTERFERENCE WITH THE FLOOR MAT. REDESIGNED ACCELERATOR PEDALS WILL BECOME AVAILABLE BEGINNING IN APRIL 2010 AND DEALERS WILL REPLACE ANY MODIFIED PEDAL WITH THE NEW PEDAL IF DESIRED. ALSO, DEALERS WILL REPLACE ANY GENUINE TOYOTA OR LEXUS ALL-WEATHER FLOOR MATS WITH REDESIGNED ALL-WEATHER MATS, OR REPURCHASE THE PREVIOUS MATS FROM OWNERS WHO DO NOT WANT THE NEW ONES. ADDITIONALLY, SOFTWARE MODIFICATIONS WILL BE INSTALLED ON CAMRY, AVALON AND LEXUS ES 350, IS 350 AND IS 250 MODELS THAT WILL ENSURE THAT THE BRAKE OVERRIDES THE ACCELERATOR IN THE EVENT BOTH BRAKE AND ACCELERATOR PEDALS ARE APPLIED. TOYOTA WILL BEGIN MAILING LETTERS TO OWNERS ON DECEMBER 31, 2009. OWNERS MAY CONTACT TOYOTA AT 1-800-331-4331, LEXUS AT 1-800-255-3987.

06V188000 · Steering:electric Power Assist System

May 31, 2006

THE INTERMEDIATE SHAFT AND SLIDING YOKE IN THE ELECTRIC POWER STEERING SYSTEM CAN CRACK WHEN LARGE FORCES ARE APPLIED AND THE CONNECTION MAY SEPARATE OR THE SLEEVE MAY FRACTURE.

Consequence & remedy

Consequence: THIS COULD RESULT IN A LOSS OF STEERING CONTROL OF THE VEHICLE.

Remedy: TOYOTA WILL REPLACE THE STEERING INTERMEDIATE SHAFT AND INSPECT THE SLIDING YOKE AND REPLACE IT IF NECESSARY. THE RECALL BEGAN ON JUNE 9, 2006. OWNERS MAY CONTACT TOYOTA AT 1-800-331-4331.

06V096000 · Air Bags

Apr 3, 2006

ON CERTAIN VEHICLES, DUE TO IMPROPER ASSEMBLY OF THE AIR BAG INFLATOR, WHICH IS USED IN THE SIDE AIR BAG, THE CURTAIN SHIELD AIR BAG, AND THE KNEE AIR BAG ASSEMBLY, SOME INFLATORS WERE PRODUCED WITH AN INSUFFICIENT AMOUNT OF THE HEATING AGENTS NECESSARY FOR PROPER AIR BAG DEPLOYMENT. IN THIS CONDITION, THE EXPANSION FORCE OF THE GAS MAY BE INSUFFICIENT TO PROPERLY INFLATE THE AIR BAG WHEN THE SRS SYSTEM IS ACTIVATED DURING A CRASH.

Consequence & remedy

Consequence: THIS MAY INCREASE THE RISK OF INJURY TO THE OCCUPANT IN THE INVOLVED SEATING POSITION IN THE EVENT OF A CRASH.

Remedy: DEALERS WILL REPLACE THE SPECIFIC SRS AIR BAG. THE RECALL BEGAN ON APRIL 6, 2006. OWNERS MAY CONTACT TOYOTA AT 1-888-270-9371, SCION AT 1-866-548-1851, OR LEXUS AT 1-800-255-3987.

04V558000 · Exterior Lighting:brake Lights:switch

Nov 22, 2004

CERTAIN PASSENGER VEHICLES MAY BE EQUIPPED WITH AN IMPROPERLY DESIGNED BRAKE LIGHT SWITCH. A SILICON OXIDE BUILD-UP OCCURS ON THE CONTACTS INSIDE THE BRAKE LIGHT SWITCH, WHICH CAN MAKE IT INOPERABLE.

Consequence & remedy

Consequence: IF THE SWITCH IS INOPERABLE, THE BRAKE LIGHTS WILL NOT ILLUMINATE AND CAN INCREASE THE RISK OF A CRASH.

Remedy: DEALERS WILL REPLACE THE BRAKE LIGHT SWITCH. THE RECALL BEGAN DURING DECEMBER 2004. OWNERS SHOULD CONTACT TOYOTA AT 1-800-331-4331.

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

3

DP22005 · Pedestrian Alert Sounds

Opened Jan 27, 2023 · Closed Aug 7, 2023

Status: closed (inferred from source dates) · Electrical System:propulsion System

NHTSA received a petition on or about July 18, 2022, requesting that Federal Motor Vehicle Safety Standard (FMVSS) 141 be applied to all electric and hybrid vehicles operating in the United States. The petition can be reviewed at NHTSA.gov under ODI Number 11486072. FMVSS 141 establishes performance requirements for pedestrian alert sounds for motor vehicles. The standard applies to hybrid and electric vehicles that have a gross vehicle weight rating of 4,536 KG or less or are defined as low-speed vehicles. The standard became fully applicable to all such vehicles manufactured on or after March 1, 2021.On January 27, 2023, NHTSA opened Defect Petition (DP) 22-005 to evaluate the subject matter described in the petition. On June 24, 2023 and as supplemented on June 25, 2023, the petitioner notified NHTSA he was withdrawing his petition. The petitioner indicated that, based on his review of data, there is no justification for asserting potential benefits that could be derived from actions sought by my petition. Based on the petitioner's withdrawal, DP22-005 is closed. Closure of this DP does not represent a determination by NHTSA regarding the subject matter of the petition.

DP13001 · Intermediate Steering Shaft Separation

Opened Feb 21, 2013 · Closed Apr 8, 2020

Status: closed (inferred from source dates) · Steering; Steering:column; Steering:linkages

The Office of Defects Investigation (ODI) received a January 2013 defect petition requesting that it open an investigation on Model Year (MY) 2004-2009 Toyota Prius vehicles to address a possible manufacturing safety defect related to the steering column intermediate shaft.During the defect petition evaluation, ODI: 1.Reviewed the petition and its enclosures; 2.Reviewed the subject steering system layout; 3.Examined the Petition Vehicle?s history, including its repair history; 4.Reviewed and followed-up potentially related consumer complaints; 5.Assessed Safety Recalls 06V-188 and 12V-537; and, 6.Requested and examined complaint, claim, field report, service history, and warranty information from Toyota.ODI's review revealed that the petition vehicle had been recalled (Recall 06V188) to remedy a defect in the system identified in the petition with the remedy taking place prior to the failure that prompted the petition. Circumstances point to incorrect reassembly of the petitioner's vehicle by those who performed the recall remedy.ODI examined the issues raised by this petition to identify any related safety defect trend in the general subject vehicle population.That review identified a low rate of related consumer complaints (twenty-five over a eight year period from a population of over 600,000 vehicles) and no pattern that would identify either a safety defect not already covered by the two existing steering safety recalls by Toyota or a systematic problem with either recall remedy.Based on this evaluation, ODI does not believe that additional investigation will lead to a finding that a defect related to motor vehicle safety exists in the subject vehicles. Therefore, in view of the need to allocate and prioritize NHTSA?s limited resources to best accomplish the agency's safety mission, the petition is denied. The denial of this petition does not constitute a finding by NHTSA that a safety-related defect does not exist. The agency reserves the right to take further action if warranted by the circumstances.For more information, see the Federal Register notice in the public file for this action (https://www.nhtsa.gov/recalls#vehicle, select NHTSA ID, enter: DP13001)The ODI reports cited above can be reviewed on-line (https://www.nhtsa.gov/recalls#vehicle) under the following NHTSA ID numbers:10407520, 10418710, 10429551, 10473654, 10478195, 10478053, 10437229, 10489425, 10510722, 10639984, 10648277, 10499778, 10712626, 10723196, 10787530, 10808124, 10838803, 11071646, 11098144, 11099507, 11102659, 11160767, 11192607, 11287550, 11287606

Additional source detail variants (3)

Steering:column

The Office of Defects Investigation (ODI) received a January 2013 defect petition requesting that it open an investigation on Model Year (MY) 2004-2009 Toyota Prius vehicles to address a possible manufacturing safety defect related to the steering column intermediate shaft.During the defect petition evaluation, ODI: 1.Reviewed the petition and its enclosures; 2.Reviewed the subject steering system layout; 3.Examined the Petition Vehicle?s history, including its repair history; 4.Reviewed and followed-up potentially related consumer complaints; 5.Assessed Safety Recalls 06V-188 and 12V-537; and, 6.Requested and examined complaint, claim, field report, service history, and warranty information from Toyota.ODI's review revealed that the petition vehicle had been recalled (Recall 06V188) to remedy a defect in the system identified in the petition with the remedy taking place prior to the failure that prompted the petition. Circumstances point to incorrect reassembly of the petitioner's vehicle by those who performed the recall remedy.ODI examined the issues raised by this petition to identify any related safety defect trend in the general subject vehicle population.That review identified a low rate of related consumer complaints (twenty-five over a eight year period from a population of over 600,000 vehicles) and no pattern that would identify either a safety defect not already covered by the two existing steering safety recalls by Toyota or a systematic problem with either recall remedy.Based on this evaluation, ODI does not believe that additional investigation will lead to a finding that a defect related to motor vehicle safety exists in the subject vehicles. Therefore, in view of the need to allocate and prioritize NHTSA?s limited resources to best accomplish the agency's safety mission, the petition is denied. The denial of this petition does not constitute a finding by NHTSA that a safety-related defect does not exist. The agency reserves the right to take further action if warranted by the circumstances.For more information, see the Federal Register notice in the public file for this action (https://www.nhtsa.gov/recalls#vehicle, select NHTSA ID, enter: DP13001)The ODI reports cited above can be reviewed on-line (https://www.nhtsa.gov/recalls#vehicle) under the following NHTSA ID numbers:10407520, 10418710, 10429551, 10473654, 10478195, 10478053, 10437229, 10489425, 10510722, 10639984, 10648277, 10499778, 10712626, 10723196, 10787530, 10808124, 10838803, 11071646, 11098144, 11099507, 11102659, 11160767, 11192607, 11287550, 11287606

Steering:linkages

The Office of Defects Investigation (ODI) received a January 2013 defect petition requesting that it open an investigation on Model Year (MY) 2004-2009 Toyota Prius vehicles to address a possible manufacturing safety defect related to the steering column intermediate shaft.During the defect petition evaluation, ODI: 1.Reviewed the petition and its enclosures; 2.Reviewed the subject steering system layout; 3.Examined the Petition Vehicle?s history, including its repair history; 4.Reviewed and followed-up potentially related consumer complaints; 5.Assessed Safety Recalls 06V-188 and 12V-537; and, 6.Requested and examined complaint, claim, field report, service history, and warranty information from Toyota.ODI's review revealed that the petition vehicle had been recalled (Recall 06V188) to remedy a defect in the system identified in the petition with the remedy taking place prior to the failure that prompted the petition. Circumstances point to incorrect reassembly of the petitioner's vehicle by those who performed the recall remedy.ODI examined the issues raised by this petition to identify any related safety defect trend in the general subject vehicle population.That review identified a low rate of related consumer complaints (twenty-five over a eight year period from a population of over 600,000 vehicles) and no pattern that would identify either a safety defect not already covered by the two existing steering safety recalls by Toyota or a systematic problem with either recall remedy.Based on this evaluation, ODI does not believe that additional investigation will lead to a finding that a defect related to motor vehicle safety exists in the subject vehicles. Therefore, in view of the need to allocate and prioritize NHTSA?s limited resources to best accomplish the agency's safety mission, the petition is denied. The denial of this petition does not constitute a finding by NHTSA that a safety-related defect does not exist. The agency reserves the right to take further action if warranted by the circumstances.For more information, see the Federal Register notice in the public file for this action (https://www.nhtsa.gov/recalls#vehicle, select NHTSA ID, enter: DP13001)The ODI reports cited above can be reviewed on-line (https://www.nhtsa.gov/recalls#vehicle) under the following NHTSA ID numbers:10407520, 10418710, 10429551, 10473654, 10478195, 10478053, 10437229, 10489425, 10510722, 10639984, 10648277, 10499778, 10712626, 10723196, 10787530, 10808124, 10838803, 11071646, 11098144, 11099507, 11102659, 11160767, 11192607, 11287550, 11287606

Steering

The Office of Defects Investigation (ODI) received a January 2013 defect petition requesting that it open an investigation on Model Year (MY) 2004-2009 Toyota Prius vehicles to address a possible manufacturing safety defect related to the steering column intermediate shaft.During the defect petition evaluation, ODI: 1.Reviewed the petition and its enclosures; 2.Reviewed the subject steering system layout; 3.Examined the Petition Vehicle?s history, including its repair history; 4.Reviewed and followed-up potentially related consumer complaints; 5.Assessed Safety Recalls 06V-188 and 12V-537; and, 6.Requested and examined complaint, claim, field report, service history, and warranty information from Toyota.ODI's review revealed that the petition vehicle had been recalled (Recall 06V188) to remedy a defect in the system identified in the petition with the remedy taking place prior to the failure that prompted the petition. Circumstances point to incorrect reassembly of the petitioner's vehicle by those who performed the recall remedy.ODI examined the issues raised by this petition to identify any related safety defect trend in the general subject vehicle population.That review identified a low rate of related consumer complaints (twenty-five over a eight year period from a population of over 600,000 vehicles) and no pattern that would identify either a safety defect not already covered by the two existing steering safety recalls by Toyota or a systematic problem with either recall remedy.Based on this evaluation, ODI does not believe that additional investigation will lead to a finding that a defect related to motor vehicle safety exists in the subject vehicles. Therefore, in view of the need to allocate and prioritize NHTSA?s limited resources to best accomplish the agency's safety mission, the petition is denied. The denial of this petition does not constitute a finding by NHTSA that a safety-related defect does not exist. The agency reserves the right to take further action if warranted by the circumstances.For more information, see the Federal Register notice in the public file for this action (https://www.nhtsa.gov/recalls#vehicle, select NHTSA ID, enter: DP13001)The ODI reports cited above can be reviewed on-line (https://www.nhtsa.gov/recalls#vehicle) under the following NHTSA ID numbers:10407520, 10418710, 10429551, 10473654, 10478195, 10478053, 10437229, 10489425, 10510722, 10639984, 10648277, 10499778, 10712626, 10723196, 10787530, 10808124, 10838803, 11071646, 11098144, 11099507, 11102659, 11160767, 11192607, 11287550, 11287606

PE05029 · Engine Stalling

Opened May 31, 2005 · Closed Oct 12, 2005

Status: closed (inferred from source dates) · Engine And Engine Cooling; Engine And Engine Cooling:engine; Unknown Or Other

ODI OPENED PE05-029 BASED ON 33 REPORTS OF ALLEGED GASOLINE ENGINE STALLING ON THE SUBJECT VEHICLES.THE SUBJECT VEHICLES ARE GASOLINE/ ELECTRIC HYBRID VEHICLES THAT CAN BE OPERATED IN GASOLINE OR ELECTRIC MODES, OR A COMBINATION OF BOTH DEPENDING ON THE POWER DEMAND.ALL REPORTS ALLEGE THAT THE GASOLINE ENGINE SHUT DOWN SUDDENLY WITHOUT WARNING.SOME OF THE COMPLAINANTS REPORTED THAT THE VEHICLE CONTINUED TO OPERATE USING THE ELECTRIC MODE FOR A PERIOD OF TIME AFTER THE GAS ENGINE STALLED AND SOME REPORTED THAT THE VEHICLE SHUT DOWN AT THE SAME TIME THAT THEY FELT THE GAS ENGINE STALLED.SOME CONSUMERS REPORTED THAT THEY WERE ABLE TO RESTART THE VEHICLE EITHER IMMEDIATELY OR AFTER ALLOWING THE VEHICLE SIT FOR A SHORT TIME, WHEREAS OTHERS REPORTED THAT THEY HAD THEIR VEHICLE TOWED.DURING PE05-029, ADDITIONAL FAILURE DATA WAS IDENTIFIED AS NOTED IN THE FAILURE REPORT SUMMARY ABOVE.THE COMPLAINT DATA REPRESENTS INCIDENTS WHERE ENGINE STALLING WAS ALLEGED OR WHERE THE VEHICLE WAS ALLEGED TO HAVE ONE OF THE VARIOUS CONDITIONS THAT CAUSES THE GAS ENGINE TO STALL.IN ITS AUGUST 26, 2005 RESPONSE TO ODI'S INFORMATION REQUEST, TOYOTA IDENTIFIED VARIOUS CONDITIONS THAT COULD CAUSE THE SUBJECT VEHICLES TO EXPERIENCE A GAS ENGINE STALL.IF THIS HAPPENS, THE DRIVER IS ALERTED BY AN AUDIBLE SOUND AND VARIOUS WARNING LIGHTS.THE VEHICLE WILL CONTINUE TO OPERATE IN THE ELECTRIC MODE AND THE ELECTRICALLY-POWERED BRAKE AND STEERING OPERATION WILL CONTINUE TO FUNCTION NORMALLY. ANALYSIS OF THE WARRANTY DATA INDICATED THAT OVER 97% OF VEHICLES EXPERIENCING A GAS ENGINE STALL RESULTED FROM AN ISSUE WITH THE PROGRAM LOGIC IN THE ELECTRONIC CONTROL MODULE (ECM) SYSTEM, WHICH MAY CAUSE THE ECM SYSTEM TO NOT START THE GAS ENGINE WHEN REQUIRED.AS A RESULT, THE VEHICLE WILL ENTER THE LIMITED OPERATION MODE DESCRIBED ABOVE.THE MAJORITY OF THE ODI COMPLAINTS ALSO INDICATED THAT THE DRIVER EXPERIENCED THIS CONDITION IN CONJUNCTION WITH THE ENGINE STALL. DURING OCTOBER 2005, TOYOTA INFORMED ODI THAT IT WOULD INITIATE A SPECIAL SERVICE CAMPAIGN (SSC) TO REPROGRAM THE ECM SOFTWARE ON APPROXIMATELY 75,000 MY 2004 AND EARLY 2005 SUBJECT VEHICLES TO ADDRESS THE GAS ENGINE STALLING CONDITION.DURING THIS SSC, DEALERS WILL ALSO APPLY SPECIAL DIELECTRIC GREASE TO A TRANSAXLE CONNECTOR TO PREVENT WATER INTRUSION WHICH MAY ALSO CAUSE SIMILAR LIMITED OPERATION CONDITIONS.BASED ON ODI'S ANALYSIS, THIS REMEDY SHOULD ADDRESS MOST OF THE INCIDENTS RESULTING IN A LIMITED OPERATION MODE.GIVEN THESE CIRCUMSTANCES, FURTHER USE OF THE AGENCY RESOURCES IN THIS MATTER DOES NOT APPEAR TO BE WARRANTED.ACCORDINGLY, THIS INVESTIGATION IS CLOSED.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT A SAFETY-RELATED DEFECT DOES NOT EXIST.THE AGENCY WILL CONTINUE TO MONITOR COMPLAINTS AND OTHER INFORMATION RELATING TO THE ALLEGED DEFECT IN THE SUBJECT VEHICLES AND TAKE FURTHER ACTION IN THE FUTURE IF WARRANTED.

Additional source detail variants (3)

Engine And Engine Cooling:engine

ODI OPENED PE05-029 BASED ON 33 REPORTS OF ALLEGED GASOLINE ENGINE STALLING ON THE SUBJECT VEHICLES.THE SUBJECT VEHICLES ARE GASOLINE/ ELECTRIC HYBRID VEHICLES THAT CAN BE OPERATED IN GASOLINE OR ELECTRIC MODES, OR A COMBINATION OF BOTH DEPENDING ON THE POWER DEMAND.ALL REPORTS ALLEGE THAT THE GASOLINE ENGINE SHUT DOWN SUDDENLY WITHOUT WARNING.SOME OF THE COMPLAINANTS REPORTED THAT THE VEHICLE CONTINUED TO OPERATE USING THE ELECTRIC MODE FOR A PERIOD OF TIME AFTER THE GAS ENGINE STALLED AND SOME REPORTED THAT THE VEHICLE SHUT DOWN AT THE SAME TIME THAT THEY FELT THE GAS ENGINE STALLED.SOME CONSUMERS REPORTED THAT THEY WERE ABLE TO RESTART THE VEHICLE EITHER IMMEDIATELY OR AFTER ALLOWING THE VEHICLE SIT FOR A SHORT TIME, WHEREAS OTHERS REPORTED THAT THEY HAD THEIR VEHICLE TOWED.DURING PE05-029, ADDITIONAL FAILURE DATA WAS IDENTIFIED AS NOTED IN THE FAILURE REPORT SUMMARY ABOVE.THE COMPLAINT DATA REPRESENTS INCIDENTS WHERE ENGINE STALLING WAS ALLEGED OR WHERE THE VEHICLE WAS ALLEGED TO HAVE ONE OF THE VARIOUS CONDITIONS THAT CAUSES THE GAS ENGINE TO STALL.IN ITS AUGUST 26, 2005 RESPONSE TO ODI'S INFORMATION REQUEST, TOYOTA IDENTIFIED VARIOUS CONDITIONS THAT COULD CAUSE THE SUBJECT VEHICLES TO EXPERIENCE A GAS ENGINE STALL.IF THIS HAPPENS, THE DRIVER IS ALERTED BY AN AUDIBLE SOUND AND VARIOUS WARNING LIGHTS.THE VEHICLE WILL CONTINUE TO OPERATE IN THE ELECTRIC MODE AND THE ELECTRICALLY-POWERED BRAKE AND STEERING OPERATION WILL CONTINUE TO FUNCTION NORMALLY. ANALYSIS OF THE WARRANTY DATA INDICATED THAT OVER 97% OF VEHICLES EXPERIENCING A GAS ENGINE STALL RESULTED FROM AN ISSUE WITH THE PROGRAM LOGIC IN THE ELECTRONIC CONTROL MODULE (ECM) SYSTEM, WHICH MAY CAUSE THE ECM SYSTEM TO NOT START THE GAS ENGINE WHEN REQUIRED.AS A RESULT, THE VEHICLE WILL ENTER THE LIMITED OPERATION MODE DESCRIBED ABOVE.THE MAJORITY OF THE ODI COMPLAINTS ALSO INDICATED THAT THE DRIVER EXPERIENCED THIS CONDITION IN CONJUNCTION WITH THE ENGINE STALL. DURING OCTOBER 2005, TOYOTA INFORMED ODI THAT IT WOULD INITIATE A SPECIAL SERVICE CAMPAIGN (SSC) TO REPROGRAM THE ECM SOFTWARE ON APPROXIMATELY 75,000 MY 2004 AND EARLY 2005 SUBJECT VEHICLES TO ADDRESS THE GAS ENGINE STALLING CONDITION.DURING THIS SSC, DEALERS WILL ALSO APPLY SPECIAL DIELECTRIC GREASE TO A TRANSAXLE CONNECTOR TO PREVENT WATER INTRUSION WHICH MAY ALSO CAUSE SIMILAR LIMITED OPERATION CONDITIONS.BASED ON ODI'S ANALYSIS, THIS REMEDY SHOULD ADDRESS MOST OF THE INCIDENTS RESULTING IN A LIMITED OPERATION MODE.GIVEN THESE CIRCUMSTANCES, FURTHER USE OF THE AGENCY RESOURCES IN THIS MATTER DOES NOT APPEAR TO BE WARRANTED.ACCORDINGLY, THIS INVESTIGATION IS CLOSED.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT A SAFETY-RELATED DEFECT DOES NOT EXIST.THE AGENCY WILL CONTINUE TO MONITOR COMPLAINTS AND OTHER INFORMATION RELATING TO THE ALLEGED DEFECT IN THE SUBJECT VEHICLES AND TAKE FURTHER ACTION IN THE FUTURE IF WARRANTED.

Engine And Engine Cooling

ODI OPENED PE05-029 BASED ON 33 REPORTS OF ALLEGED GASOLINE ENGINE STALLING ON THE SUBJECT VEHICLES.THE SUBJECT VEHICLES ARE GASOLINE/ ELECTRIC HYBRID VEHICLES THAT CAN BE OPERATED IN GASOLINE OR ELECTRIC MODES, OR A COMBINATION OF BOTH DEPENDING ON THE POWER DEMAND.ALL REPORTS ALLEGE THAT THE GASOLINE ENGINE SHUT DOWN SUDDENLY WITHOUT WARNING.SOME OF THE COMPLAINANTS REPORTED THAT THE VEHICLE CONTINUED TO OPERATE USING THE ELECTRIC MODE FOR A PERIOD OF TIME AFTER THE GAS ENGINE STALLED AND SOME REPORTED THAT THE VEHICLE SHUT DOWN AT THE SAME TIME THAT THEY FELT THE GAS ENGINE STALLED.SOME CONSUMERS REPORTED THAT THEY WERE ABLE TO RESTART THE VEHICLE EITHER IMMEDIATELY OR AFTER ALLOWING THE VEHICLE SIT FOR A SHORT TIME, WHEREAS OTHERS REPORTED THAT THEY HAD THEIR VEHICLE TOWED.DURING PE05-029, ADDITIONAL FAILURE DATA WAS IDENTIFIED AS NOTED IN THE FAILURE REPORT SUMMARY ABOVE.THE COMPLAINT DATA REPRESENTS INCIDENTS WHERE ENGINE STALLING WAS ALLEGED OR WHERE THE VEHICLE WAS ALLEGED TO HAVE ONE OF THE VARIOUS CONDITIONS THAT CAUSES THE GAS ENGINE TO STALL.IN ITS AUGUST 26, 2005 RESPONSE TO ODI'S INFORMATION REQUEST, TOYOTA IDENTIFIED VARIOUS CONDITIONS THAT COULD CAUSE THE SUBJECT VEHICLES TO EXPERIENCE A GAS ENGINE STALL.IF THIS HAPPENS, THE DRIVER IS ALERTED BY AN AUDIBLE SOUND AND VARIOUS WARNING LIGHTS.THE VEHICLE WILL CONTINUE TO OPERATE IN THE ELECTRIC MODE AND THE ELECTRICALLY-POWERED BRAKE AND STEERING OPERATION WILL CONTINUE TO FUNCTION NORMALLY. ANALYSIS OF THE WARRANTY DATA INDICATED THAT OVER 97% OF VEHICLES EXPERIENCING A GAS ENGINE STALL RESULTED FROM AN ISSUE WITH THE PROGRAM LOGIC IN THE ELECTRONIC CONTROL MODULE (ECM) SYSTEM, WHICH MAY CAUSE THE ECM SYSTEM TO NOT START THE GAS ENGINE WHEN REQUIRED.AS A RESULT, THE VEHICLE WILL ENTER THE LIMITED OPERATION MODE DESCRIBED ABOVE.THE MAJORITY OF THE ODI COMPLAINTS ALSO INDICATED THAT THE DRIVER EXPERIENCED THIS CONDITION IN CONJUNCTION WITH THE ENGINE STALL. DURING OCTOBER 2005, TOYOTA INFORMED ODI THAT IT WOULD INITIATE A SPECIAL SERVICE CAMPAIGN (SSC) TO REPROGRAM THE ECM SOFTWARE ON APPROXIMATELY 75,000 MY 2004 AND EARLY 2005 SUBJECT VEHICLES TO ADDRESS THE GAS ENGINE STALLING CONDITION.DURING THIS SSC, DEALERS WILL ALSO APPLY SPECIAL DIELECTRIC GREASE TO A TRANSAXLE CONNECTOR TO PREVENT WATER INTRUSION WHICH MAY ALSO CAUSE SIMILAR LIMITED OPERATION CONDITIONS.BASED ON ODI'S ANALYSIS, THIS REMEDY SHOULD ADDRESS MOST OF THE INCIDENTS RESULTING IN A LIMITED OPERATION MODE.GIVEN THESE CIRCUMSTANCES, FURTHER USE OF THE AGENCY RESOURCES IN THIS MATTER DOES NOT APPEAR TO BE WARRANTED.ACCORDINGLY, THIS INVESTIGATION IS CLOSED.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT A SAFETY-RELATED DEFECT DOES NOT EXIST.THE AGENCY WILL CONTINUE TO MONITOR COMPLAINTS AND OTHER INFORMATION RELATING TO THE ALLEGED DEFECT IN THE SUBJECT VEHICLES AND TAKE FURTHER ACTION IN THE FUTURE IF WARRANTED.

Unknown Or Other

ODI OPENED PE05-029 BASED ON 33 REPORTS OF ALLEGED GASOLINE ENGINE STALLING ON THE SUBJECT VEHICLES.THE SUBJECT VEHICLES ARE GASOLINE/ ELECTRIC HYBRID VEHICLES THAT CAN BE OPERATED IN GASOLINE OR ELECTRIC MODES, OR A COMBINATION OF BOTH DEPENDING ON THE POWER DEMAND.ALL REPORTS ALLEGE THAT THE GASOLINE ENGINE SHUT DOWN SUDDENLY WITHOUT WARNING.SOME OF THE COMPLAINANTS REPORTED THAT THE VEHICLE CONTINUED TO OPERATE USING THE ELECTRIC MODE FOR A PERIOD OF TIME AFTER THE GAS ENGINE STALLED AND SOME REPORTED THAT THE VEHICLE SHUT DOWN AT THE SAME TIME THAT THEY FELT THE GAS ENGINE STALLED.SOME CONSUMERS REPORTED THAT THEY WERE ABLE TO RESTART THE VEHICLE EITHER IMMEDIATELY OR AFTER ALLOWING THE VEHICLE SIT FOR A SHORT TIME, WHEREAS OTHERS REPORTED THAT THEY HAD THEIR VEHICLE TOWED.DURING PE05-029, ADDITIONAL FAILURE DATA WAS IDENTIFIED AS NOTED IN THE FAILURE REPORT SUMMARY ABOVE.THE COMPLAINT DATA REPRESENTS INCIDENTS WHERE ENGINE STALLING WAS ALLEGED OR WHERE THE VEHICLE WAS ALLEGED TO HAVE ONE OF THE VARIOUS CONDITIONS THAT CAUSES THE GAS ENGINE TO STALL.IN ITS AUGUST 26, 2005 RESPONSE TO ODI'S INFORMATION REQUEST, TOYOTA IDENTIFIED VARIOUS CONDITIONS THAT COULD CAUSE THE SUBJECT VEHICLES TO EXPERIENCE A GAS ENGINE STALL.IF THIS HAPPENS, THE DRIVER IS ALERTED BY AN AUDIBLE SOUND AND VARIOUS WARNING LIGHTS.THE VEHICLE WILL CONTINUE TO OPERATE IN THE ELECTRIC MODE AND THE ELECTRICALLY-POWERED BRAKE AND STEERING OPERATION WILL CONTINUE TO FUNCTION NORMALLY. ANALYSIS OF THE WARRANTY DATA INDICATED THAT OVER 97% OF VEHICLES EXPERIENCING A GAS ENGINE STALL RESULTED FROM AN ISSUE WITH THE PROGRAM LOGIC IN THE ELECTRONIC CONTROL MODULE (ECM) SYSTEM, WHICH MAY CAUSE THE ECM SYSTEM TO NOT START THE GAS ENGINE WHEN REQUIRED.AS A RESULT, THE VEHICLE WILL ENTER THE LIMITED OPERATION MODE DESCRIBED ABOVE.THE MAJORITY OF THE ODI COMPLAINTS ALSO INDICATED THAT THE DRIVER EXPERIENCED THIS CONDITION IN CONJUNCTION WITH THE ENGINE STALL. DURING OCTOBER 2005, TOYOTA INFORMED ODI THAT IT WOULD INITIATE A SPECIAL SERVICE CAMPAIGN (SSC) TO REPROGRAM THE ECM SOFTWARE ON APPROXIMATELY 75,000 MY 2004 AND EARLY 2005 SUBJECT VEHICLES TO ADDRESS THE GAS ENGINE STALLING CONDITION.DURING THIS SSC, DEALERS WILL ALSO APPLY SPECIAL DIELECTRIC GREASE TO A TRANSAXLE CONNECTOR TO PREVENT WATER INTRUSION WHICH MAY ALSO CAUSE SIMILAR LIMITED OPERATION CONDITIONS.BASED ON ODI'S ANALYSIS, THIS REMEDY SHOULD ADDRESS MOST OF THE INCIDENTS RESULTING IN A LIMITED OPERATION MODE.GIVEN THESE CIRCUMSTANCES, FURTHER USE OF THE AGENCY RESOURCES IN THIS MATTER DOES NOT APPEAR TO BE WARRANTED.ACCORDINGLY, THIS INVESTIGATION IS CLOSED.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT A SAFETY-RELATED DEFECT DOES NOT EXIST.THE AGENCY WILL CONTINUE TO MONITOR COMPLAINTS AND OTHER INFORMATION RELATING TO THE ALLEGED DEFECT IN THE SUBJECT VEHICLES AND TAKE FURTHER ACTION IN THE FUTURE IF WARRANTED.