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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.

About this comparison →

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

What owners actually said

610 reports
104,204 miles · Jul 11, 2010
Exterior Lighting

MAJOR PROBLEM WITH THE VEHICLE'S HEADLIGHTS. THEY INTERMITTENTLY TURN THEMSELVES OFF WITHOUT ANY WARNING. TRIED REPLACING THEM PER THE MANUAL INSTRUCTIONS BUT THE INSTALLED LAMPS ARE DIFFERENT THAN THE MANUAL, SO REPLACING THEM IS NOT AN OPTION. I CONSIDER THIS A MAJOR SAFETY DEFECT. THESE LAMPS ARE SUPPOSED TO LAST THE LIFE…

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MAJOR PROBLEM WITH THE VEHICLE'S HEADLIGHTS. THEY INTERMITTENTLY TURN THEMSELVES OFF WITHOUT ANY WARNING. TRIED REPLACING THEM PER THE MANUAL INSTRUCTIONS BUT THE INSTALLED LAMPS ARE DIFFERENT THAN THE MANUAL, SO REPLACING THEM IS NOT AN OPTION. I CONSIDER THIS A MAJOR SAFETY DEFECT. THESE LAMPS ARE SUPPOSED TO LAST THE LIFE OF THE CAR. ANY HEADLAMP THAT STOPS WORKING WITHOUT WARNING IS A SAFETY ISSUE. I HAVE NEVER HEARD OF THIS HAPPENING BEFORE WITH ANY CAR. YOU CAN MAKE THE LIGHT COME BACK ON BY TURNING ALL THE LIGHTS OFF AND THEN ON AGAIN. THIS DEFECT IS GOING TO CAUSE A MAJOR ACCIDENT AND FOLKS ARE GOING TO GET HURT OR WORSE. *TR

NHTSA ODI #10342471

121,000 miles · Jul 10, 2010
Exterior Lighting

MY COMPLAINT HAS TO DO WITH THE HIGH ENERGY DISCHARGE (XENON) HEADLIGHTS ON MY 2004 TOYOTA PRIUS. BEGINNING SOMETIME IN FEBRUARY 2010 MY WIFE AND I BEGAN TO NOTICE THAT THE DRIVERS SIDE HEADLIGHT WOULD SHUT DOWN AFTER THE LIGHTS HAD BEEN ON FOR A FEW MINUTES. IF THE HEADLIGHTS WERE QUICKLY TURNED OFF AND THEN BACK ON (SAY, WHI…

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MY COMPLAINT HAS TO DO WITH THE HIGH ENERGY DISCHARGE (XENON) HEADLIGHTS ON MY 2004 TOYOTA PRIUS. BEGINNING SOMETIME IN FEBRUARY 2010 MY WIFE AND I BEGAN TO NOTICE THAT THE DRIVERS SIDE HEADLIGHT WOULD SHUT DOWN AFTER THE LIGHTS HAD BEEN ON FOR A FEW MINUTES. IF THE HEADLIGHTS WERE QUICKLY TURNED OFF AND THEN BACK ON (SAY, WHILE STOPPED AT A TRAFFIC LIGHT), BOTH HEADLIGHTS WOULD WORK JUST FINE FOR A WHILE. I TRIED TO REPLACE THE BULBS (D2R TYPE XENON BULBS) WHICH I PURCHASED AT A LOCAL CAR PARTS STORE FOR APPROXIMATELY $90 EACH. AFTER TRYING TO FOLLOW THE INSTRUCTIONS FOR REPLACING THE BULBS (FOUND IN THE OWNERS MANUAL), I WAS UNABLE TO OPEN THE BULB HOLDERS. WHEN I HAD THE CAR AT THE DEALERSHIP (CAPITOL TOYOTA) FOR SERVICE IN LATE APRIL 2010, I ASKED IF THEY COULD FIX THE HEADLIGHTS. THE SERVICE REP TOLD ME THAT MERE DIAGNOSIS OF THE PROBLEM WOULD COST $600, WITH ANY BALLAST OR BULB REPLACEMENT ADDED TO THAT COST. I HAVE NEVER PAID MORE THAN ABOUT $40 TO REPLACE BOTH OF MY VEHICLE HEADLIGHTS PRIOR TO THIS. I APPRECIATE THAT THESE BULBS SHOULD COST MORE THAN HALOGEN OR OTHER TYPES, BUT THE COSTS I'M ENCOUNTERING ARE OUTLANDISH. IN THE MEAN TIME, WE ARE STILL DRIVING THE CAR WITH THE PROBLEM. HEADLIGHTS WORK FOR FIVE TO 10 MINUTES, AND THEN ONE, AND NOW, SOMETIMES THE OTHER HEADLIGHT WILL SHUT DOWN. RECENTLY, OUR DAUGHTER ARRIVED BACK FROM A BRIEF TRIP COMPLAINING THAT THE HEADLIGHTS WERE VERY DIM. I FOUND OUT THAT NEITHER HEADLIGHT WAS WORKING - THE ONLY LIGHTS ON THE FRONT OF THE CAR WERE THE FOG LAMPS. WE NOW DO NOT DRIVE THIS CAR AT NIGHT, AND WONDER HOW WE WILL FIX THIS PROBLEM. *TR

NHTSA ODI #10342410

86,831 miles · Jul 2, 2010
Service Brakes, Electric

WE OWN A 2004 TOYOTA PRIUS AND HAVE BEEN VERY PLEASED WITH IT UNTIL IT RECENTLY EXPERIENCED A SUDDEN BRAKE FAILURE. AFTER STOPPING AT A REST STOP AND PREPARING TO RETURN TO THE INTERSTATE, MY WIFE EXPERIENCED A COMPLETE BRAKE FAILURE AS SHE DROVE THE VEHICLE IN REVERSE FROM THE PARKING AREA. SHE THEN DROVE THE VEHICLE FORWARD…

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WE OWN A 2004 TOYOTA PRIUS AND HAVE BEEN VERY PLEASED WITH IT UNTIL IT RECENTLY EXPERIENCED A SUDDEN BRAKE FAILURE. AFTER STOPPING AT A REST STOP AND PREPARING TO RETURN TO THE INTERSTATE, MY WIFE EXPERIENCED A COMPLETE BRAKE FAILURE AS SHE DROVE THE VEHICLE IN REVERSE FROM THE PARKING AREA. SHE THEN DROVE THE VEHICLE FORWARD TO GET IT OUT OF THE TRAFFIC LANE AND CONTINUED TO NOT HAVE BRAKES. THE VEHICLE WAS TOWED TO AMARILLO, TX WHERE THE TOYOTA DEALER REPAIRED THE VEHICLE BY REPLACING THE STROKE SENSOR (SCANNED SYSTEM CODE C1247). *TR

NHTSA ODI #10341294

82,000 miles · Jul 2, 2010
Exterior Lighting

INTERMITTENT HEADLIGHT FAILURE ON MY 2004 TOYOTA PRIUS. IT FIRST HAPPENED AROUND 67,000 MILES WHEN BOTH HEADLIGHTS WENT OUT AT ONCE (AT NIGHT!). FLICKING THE SWITCH DID MAKE THEM COME BACK ON. AFTER THAT, THE FAILURE HAS BEEN INCREASING, MAINLY WITH THE PASSENGER SIDE HEADLIGHT. TURNING THE SWITCH NO LONGER ALWAYS WORKS TO …

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INTERMITTENT HEADLIGHT FAILURE ON MY 2004 TOYOTA PRIUS. IT FIRST HAPPENED AROUND 67,000 MILES WHEN BOTH HEADLIGHTS WENT OUT AT ONCE (AT NIGHT!). FLICKING THE SWITCH DID MAKE THEM COME BACK ON. AFTER THAT, THE FAILURE HAS BEEN INCREASING, MAINLY WITH THE PASSENGER SIDE HEADLIGHT. TURNING THE SWITCH NO LONGER ALWAYS WORKS TO TURN THE LIGHT BACK ON. I CAN;T ALWAYS TELL THAT IT IS OFF IF THEY ARE ON FOR ME TO ME SEEN (SUCH AS IN RAIN) RATHER THAN TO ALLOW ME TO SEE. THIS IS INCREDIBLY DANGEROUS. I CAN;T DRIVE THE CAR AT NIGHT RELIABLY NOW AND WHAT ABOUT IN RAIN (WHICH IS NOT AS EASILY PREDICTABLE AS "DAY/NIGHT")? THIS IS CLEARLY NOT A RARE OCCURRENCE. TOYOTA NEEDS TO STEP UP HERE. BY THE WAY, I'VE ALREADY HAD TO SPEND $800 TO FIX MY MULTIFUNCTION DISPLAY WHICH FAILURE IS ALSO WELL DOCUMENTED. *TR

NHTSA ODI #10341288

32,000 miles · Jun 16, 2010
Service Brakes, HydraulicCrash

TL* THE CONTACT OWNS A 2004 TOYOTA PRIUS. WHILE ATTEMPTING TO STOP THE VEHICLE, THE BRAKES WOULD NOT ENGAGE AND THE CONTACT CRASHED INTO A VEHICLE AHEAD OF HER. THE VEHICLE SUSTAINED EXTENSIVE FRONT END DAMAGE BUT SHE WAS ABLE TO DRIVE THE VEHICLE TO HER RESIDENCE. THE VEHICLE WAS NOT DIAGNOSED AND SHE HAD NOT CONTACTED THE DEA…

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TL* THE CONTACT OWNS A 2004 TOYOTA PRIUS. WHILE ATTEMPTING TO STOP THE VEHICLE, THE BRAKES WOULD NOT ENGAGE AND THE CONTACT CRASHED INTO A VEHICLE AHEAD OF HER. THE VEHICLE SUSTAINED EXTENSIVE FRONT END DAMAGE BUT SHE WAS ABLE TO DRIVE THE VEHICLE TO HER RESIDENCE. THE VEHICLE WAS NOT DIAGNOSED AND SHE HAD NOT CONTACTED THE DEALER OR MANUFACTURER FOR REPAIRS. THE FAILURE AND CURRENT MILEAGES WERE 32,000.

NHTSA ODI #10336622

81 miles · Jun 7, 2010
Exterior Lighting

THE HEADLIGHTS ON OUR 2004 PRIUS (80,000 MILES) HAVE GONE ON AND OFF INTERMITTENTLY OVER THE PAST FEW YEARS. HOWEVER, IT WAS NOT UNTIL SATURDAY NIGHT WHILE WE WERE ON THE FREEWAY WHEN BOTH LIGHTS WENT OUT SIMULTANEOUSLY. WE WERE TOLD BY THE DEALER THAT THIS HAPPENS QUITE OFTEN AND THE A NEW BULB WOULD FIX THE PROBLEM. AT $800…

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THE HEADLIGHTS ON OUR 2004 PRIUS (80,000 MILES) HAVE GONE ON AND OFF INTERMITTENTLY OVER THE PAST FEW YEARS. HOWEVER, IT WAS NOT UNTIL SATURDAY NIGHT WHILE WE WERE ON THE FREEWAY WHEN BOTH LIGHTS WENT OUT SIMULTANEOUSLY. WE WERE TOLD BY THE DEALER THAT THIS HAPPENS QUITE OFTEN AND THE A NEW BULB WOULD FIX THE PROBLEM. AT $800.00 TO REPLACE A DEFECTIVE PART, I THINK THIS IS EXCESSIVE AND UNNECESSARY. *TR

NHTSA ODI #10335048

56,767 miles · Jun 2, 2010
Vehicle Speed Control

TL*THE CONTACT OWNS A 2004 TOYOTA PRIUS. WHILE DRIVING AT APPROXIMATELY 20 MPH, THE FLOOR MAT BECAME STUCK INSIDE THE ACCELERATOR PAD. THE VEHICLE ACCELERATED AND THE CONTACT PRESSED A BUTTON TO TURN OFF THE VEHICLE. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALERSHIP BUT THE DEALER COULD NOT DUPLICATE THE FAILURE. THE FAILURE OCC…

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TL*THE CONTACT OWNS A 2004 TOYOTA PRIUS. WHILE DRIVING AT APPROXIMATELY 20 MPH, THE FLOOR MAT BECAME STUCK INSIDE THE ACCELERATOR PAD. THE VEHICLE ACCELERATED AND THE CONTACT PRESSED A BUTTON TO TURN OFF THE VEHICLE. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALERSHIP BUT THE DEALER COULD NOT DUPLICATE THE FAILURE. THE FAILURE OCCURRED TWO TIMES AFTER RECALL REPAIR WAS PERFORMED FOR RECALL 09V388000 (VEHICLE SPEED CONTROL: ACCELERATOR PEDAL). THE FAILURE MILEAGE WAS 56,767. THE CURRENT MILEAGE WAS 71,734.

NHTSA ODI #10334230

50,000 miles · May 31, 2010
Parking BrakePower Train

MY 2004 TOYOTA PRIUS HAS LEFT ME STRANDED FOR 15 MINUTE PERIODS OF TIME WHILE PARKED ON MY STREET. ALL THE DASHBOARD LIGHTS COME ON AS WELL AS THE FOLLOWING RED WARNING "CAUTION - TRANSMISSION "P" LOCK MECHANISM IS ABNORMAL. PARK IN A FLAT PLACE AND APPLY BRAKE." I WAS PARKED ON A MILD INCLINE AND I ALWAYS USE MY PARKING BRA…

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MY 2004 TOYOTA PRIUS HAS LEFT ME STRANDED FOR 15 MINUTE PERIODS OF TIME WHILE PARKED ON MY STREET. ALL THE DASHBOARD LIGHTS COME ON AS WELL AS THE FOLLOWING RED WARNING "CAUTION - TRANSMISSION "P" LOCK MECHANISM IS ABNORMAL. PARK IN A FLAT PLACE AND APPLY BRAKE." I WAS PARKED ON A MILD INCLINE AND I ALWAYS USE MY PARKING BRAKE. THIS HOWEVER MAKES ME SUSPICIOUS OF WHETHER THE PARKING BRAKE IS HARDY ENOUGH TO WORK WHEN PARKED ON THE CROWN OF A STREET PARKING SPACE. I APPLIED AND RE-APPLIED MY PARKING BRAKE WITHOUT SUCCESS. I OPEN AND CLOSED THE HOOD WITHOUT SUCCESS. I OPEN AND CLOSED MY DOOR WITHOUT SUCCESS. I PLACED ALL MY PASSENGER SEAT ITEMS ON THE FLOOR WITHOUT SUCCESS. I HELD THE IGNITION BUTTON WITHOUT SUCCESS. I PLACED MY KEY FOB INTO THE IGNITION WITHOUT SUCCESS. AND WHEN TRYING TO REMOVE MY KEY FOB SO I COULD GO CALL A TOW TRUCK, THE ENTIRE DASHBOARD HOUSING FOR THE IGNITION KEY CAME LOOSE AND DIS-ARTICULATED IN MY HAND. I JUST CAREFULLY PUSHED THE PLASTIC HOUSING BACK INTO THE DASHBOARD.... HOWEVER, THAT WAS DEPRESSING TO SEE. FINALLY, AFTER ALL THE TINKERING FOR 15 MINUTES, MY CAR FINALLY TURNED OFF. I WAS THEN ABLE TO TURN IT BACK ON AND DRIVE AWAY WITHOUT A PROBLEM. IN RETROSPECT, THIS HAS HAPPENED ON AT LEAST 4 OCCASIONS SINCE DECEMBER 24, 2009 AND I JUST ASSUMED THAT DURING THE BOUT WITH MY INJURED LEG THAT I WAS NOT ADEQUATELY PLACING ENOUGH FORCE ON THE PARKING BRAKE..... BUT SHOULD THIS HAPPEN SO EASILY?? I HAVE SEEN MANY OTHER SIMILAR COMPLAINTS ONLINE. I WOULD LIKE TO KNOW IF THIS IS PART OF THE WHOLE SAFETY ISSUES WITH CARS NOT BEING ABLE TO STOP WHILE RUNNING. THANKS. *TR

NHTSA ODI #10333915

102,595 miles · May 28, 2010
Vehicle Speed Control

TL*THE CONTACT OWNS A 2004 TOYOTA PRIUS. WHILE DRIVING AT APPROXIMATELY 55 MPH THE CONTACT DEPRESSED THE ACCELERATOR PEDAL AND THE VEHICLE SURGED FORWARD. THE VEHICLE WOULD NOT STOP UNTIL REPEATED PRESSURE WAS APPLIED TO THE BRAKES. THE CONTACT CALLED THE MANUFACTURER WHO STATED THAT THE ISSUE WAS NOT A BIG DEAL. THE FAILURE AND…

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TL*THE CONTACT OWNS A 2004 TOYOTA PRIUS. WHILE DRIVING AT APPROXIMATELY 55 MPH THE CONTACT DEPRESSED THE ACCELERATOR PEDAL AND THE VEHICLE SURGED FORWARD. THE VEHICLE WOULD NOT STOP UNTIL REPEATED PRESSURE WAS APPLIED TO THE BRAKES. THE CONTACT CALLED THE MANUFACTURER WHO STATED THAT THE ISSUE WAS NOT A BIG DEAL. THE FAILURE AND CURRENT MILEAGES WERE 102,595.

NHTSA ODI #10332696

69,042 miles · May 26, 2010
Engine And Engine Cooling

DRIVING HOME AT NIGHT ON THE 405 FREEWAY AT APPROX. 65MPH, SUDDENLY ALL THE DASH WARNING LIGHTS ILLUMINATED, INCLUDING THE MIL SYMBOL, ALONG WITH A WARNING SYMBOL ON THE NAVIGATION SCREEN. I PULLED OFF THE FREEWAY AND PARKED AT THE CURB. AFTER CHECKING THE OWNERS MANUAL, I SLOWLY DROVE THE REST OF THE WAY HOME ON SURFACE STREETS…

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DRIVING HOME AT NIGHT ON THE 405 FREEWAY AT APPROX. 65MPH, SUDDENLY ALL THE DASH WARNING LIGHTS ILLUMINATED, INCLUDING THE MIL SYMBOL, ALONG WITH A WARNING SYMBOL ON THE NAVIGATION SCREEN. I PULLED OFF THE FREEWAY AND PARKED AT THE CURB. AFTER CHECKING THE OWNERS MANUAL, I SLOWLY DROVE THE REST OF THE WAY HOME ON SURFACE STREETS. THE NEXT MORNING (MONDAY) I DROVE MY CAR TO MILLER TOYOTA IN CULVER CITY. THE PRIMARY DIAGNOSIS WAS FAILURE OF THE INVERTER COOLANT PUMP, WHICH WAS REPLACED UNDER THE TERMS OF MY TOYOTA PLATINUM EXTENDED WARRANTY. HOWEVER, UPON FURTHER RESEARCH, I DISCOVERED THAT TOYOTA HAD ISSUED A TECHNICAL SERVICE BULLETIN (TSB) COVERING THIS VERY PART, ON JANUARY 26, 2007, INDICATING THAT THEY WERE AWARE OF THIS FAILURE-PRONE PART, AND THAT AN "IMPROVED" REPLACEMENT ASSEMBLY WAS NOW AVAILABLE TO ADDRESS THE ISSUE. IN ADDITION, REPLACEMENT WOULD BE COVERED UNDER THEIR 5-YEAR/60,000 MILE TOYOTA POWERTRAIN WARRANTY. APPROXIMATELY ONE MONTH LATER, ON MAY 15, 2010, WHILE DRIVING MY FATHER'S 2004 PRIUS TO HAVE NEW TIRES INSTALLED, THE SAME SEQUENCE OF EVENTS OCCURRED. I IMMEDIATELY DROVE THE VEHICLE TO THE NEAREST DEALER, SANTA MONICA TOYOTA, WHERE IT WAS DIAGNOSED WITH THE SAME FAILURE CODE, P0A93 (INVERTER COOLING SYSTEM PERFORMANCE). ALTHOUGH THE VEHICLE HAD ONLY 34,242 MILES ON IT, IT WAS NOT COVERED UNDER THE POWERTRAIN WARRANTY, AS THE TIME LIMIT OF 60 MONTHS HAD EXPIRED. NO AMOUNT OF DISCUSSION WITH THE DEALER OR TOYOTA'S CUSTOMER EXPERIENCE CENTER COULD CONVINCE THEM THAT THIS PART SHOULD BE CONSIDERED PART OF THE HYBRID SYSTEM, AND AS SUCH BE COVERED UNDER THEIR 7-YEAR/100,000 HYBRID WARRANTY (DESPITE IT BEING NAMED THE HYBRID INVERTER COOLANT PUMP). ON-LINE PRIUS-RELATED CHAT ROOMS ARE FULL OF IDENTICAL SITUATIONS INVOLVING THIS PART. CLEARLY, TOYOTA KNOWS THIS PART IS PRONE TO PREMATURE FAILURE, BUT CONTINUES TO TREAT IT AS A "SECRET WARRANTY" ITEM IN ORDER TO AVOID HAVING TO ISSUE A FORMAL RECALL. *TR

NHTSA ODI #10332367

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.