VEHICLE STALLED TWICE WITHOUT WARNING. HAD TO BE TOWED TO DEALER.
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 →How this year compares
Owner complaints by model year
Compare all Prius years →Counts vary with age, sales and reporting. They are not failure rates.
What owners reported most
All reported categories
Tap a category to read its complaints. One report may name several components.
When problems were reported
Mileage at the reported incident
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.
What owners actually said
610 reportsI DROVE MY TOYOTA PRIUS FROM FLORIDA TO COLORADO. AFTER ABOUT 2100 MILES THE CAR STALLED. I WAS STUCK ON THE HIGHWAY FOR ABOUT 2 HOURS AT A TEMPERATURE OF 15 DEGREES UNTIL I GOT TOWED TO A TOYOTA DEALER. THE DEALER RECHARGED THE BATTERY, WHICH COMPLETELY DISCHARGED WHILE I SAT IN THE STALLED CAR WITH THE HEATER ON, AND THE PR…
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I DROVE MY TOYOTA PRIUS FROM FLORIDA TO COLORADO. AFTER ABOUT 2100 MILES THE CAR STALLED. I WAS STUCK ON THE HIGHWAY FOR ABOUT 2 HOURS AT A TEMPERATURE OF 15 DEGREES UNTIL I GOT TOWED TO A TOYOTA DEALER. THE DEALER RECHARGED THE BATTERY, WHICH COMPLETELY DISCHARGED WHILE I SAT IN THE STALLED CAR WITH THE HEATER ON, AND THE PROBLEM WAS GONE.
ON 4/7/05 I WAS TRAVELING ON THE NJ PARKWAY AND ALL OF A SUDDEN FOR NO REASON MY 2004 PRIUS ENGINE STALLED NO GAS TO ENGINE ONLY ELECTRIC POWER THEN THE ELECTRIC POWER SLOWLY IN ABOUT LEST THAN 2 MINUTES WENT TO ZERO AND THEN I HAD TO COAST TO A SAFE SPOT TO PULL OVER ON THE SHOULDER. LUCKILY I WAS ALREADY TRAVELING IN THE SLOW…
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ON 4/7/05 I WAS TRAVELING ON THE NJ PARKWAY AND ALL OF A SUDDEN FOR NO REASON MY 2004 PRIUS ENGINE STALLED NO GAS TO ENGINE ONLY ELECTRIC POWER THEN THE ELECTRIC POWER SLOWLY IN ABOUT LEST THAN 2 MINUTES WENT TO ZERO AND THEN I HAD TO COAST TO A SAFE SPOT TO PULL OVER ON THE SHOULDER. LUCKILY I WAS ALREADY TRAVELING IN THE SLOW RIGHT LANE, ALTHOUGH AT 5 PM RUSH HOUR ITS STILL GOING 65+ MPH, I COASTED DOWN TO 40 MPH UNTIL I FINALLY CAME TO A SHOULDER IN THE RIGHT LANE. I CHECKED FOR ANYTHING LEAKING NOTHING, AND ABOUT 10 MINUTES LATER IT STARTED UP. NOW ALL WARNING LIGHTS WENT ON THE ENGINE WARNING FAILURE LIGHT WHICH SAID TO BRING TO DEALER RIGHT AWAY WAS ON. I BROUGHT TO DEALER THE NEXT DAY A WAS STILL ABLE TO DRIVE IT. THEY EVENTUALLY FIXED THE PROBLEM THEY SAID IT WAS A COMPUTER SOFTWARE PROBLEM. THEY HAD IT FROM 4/8 TO 4/13. IT WAS A VERY SCARY SITUATION LUCKLY I WAS NOT IN THE FAST LANE WERE I WOULD HAVE BEEN STUCK IN THE MIDDLE OF FAST DRIVING TRAFFIC. I JUST WANTED TO SUBMIT THIS TO PUT ON RECORD JUST INCASE THERE IS A BIGGER PROBLEM WITH OTHER VEHICLES. THE CAR HAS RUN FINE SINCE AND NO PROBLEMS SO FAR. I READ THE STORY FROM VERIZON ONLINE.
1. I WAS DRIVING AROUND 30 TO 40 MPH AND THE GAS ENGINE FAILED SUDDENLY DURING THE COURSE OF NORMAL DRIVING, LEAVING ONLY THE ELECTRICAL ENGINE RUNNING. AT THE SAME TIME THE ENGINE FAILED, MANY LIGHTS TURNED ON ON THE DASHBOARD. 2. I WAS ON A CANYON ROAD IN THE LOS ANGELES MOUNTAINS WHEN IT FAILED, WHICH WAS A SINGLE LANE ROAD…
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1. I WAS DRIVING AROUND 30 TO 40 MPH AND THE GAS ENGINE FAILED SUDDENLY DURING THE COURSE OF NORMAL DRIVING, LEAVING ONLY THE ELECTRICAL ENGINE RUNNING. AT THE SAME TIME THE ENGINE FAILED, MANY LIGHTS TURNED ON ON THE DASHBOARD. 2. I WAS ON A CANYON ROAD IN THE LOS ANGELES MOUNTAINS WHEN IT FAILED, WHICH WAS A SINGLE LANE ROAD EACH WAY WITH NOWHERE TO PULL OFF. LUCKILY, I HAD JUST REACHED ON OF THE CRESTS IN THE CANYON WHEN THE ENGINE FAILED, SO WITH THE ELECTRICAL ENGINE I WAS ABLE TO COAST TO A SIDE STREET. ONCE ON THE SIDE STREET, THE ELECTRICAL ENGINE DIED QUICKLY, PROBABLY BECAUSE OF THE STEEP SLOPE UPWARDS OF THE STREET. 3. I TRIED TO TURN OFF THE CAR AND IT WOULDN'T TURN OFF, SO I POPPED THE HOOD AND GOT OUT TO SEE IF THERE WAS AN OBVIOUS PROBLEM. FINDING NO PROBLEM I COULD SEE I WENT BACK INSIDE THE CAR AND HELD DOWN THE POWER BUTTON UNTIL THE VEHICLE TURNED OFF FINALLY. WHEN THE VEHICLE TURNED BACK ON, THE ENGINE SEMPT TO WORK NORMALLY, AND I IMMEDIATELY WENT TO THE NEAREST TOYOTA DEALER. THEY SAID THEY HAD HEARD OF THE PROBLEM ONCE OR TWICE BEFORE AND IT REQUIRES A SOFTWARE UPDATE TO THE CAR. I WAS WEARY OF THEIR PROPOSED SOLUTION SINCE IT IS SUCH A DANGEROUS PROBLEM, BUT THAT'S ALL THEY SAID THEY COULD DO, SO I TOLD THEM TO GO AHEAD.
SUMMARY: INTERNAL COMBUSTION ENGINE DIED WHILE DRIVING. LOTS OF INDICATOR LIGHTS ON DASH, AND MESSAGE APPEARED ON MULTIFUNCTION DISPLAY. WAS ABLE TO GET TO A SAFE LOCATION ON BATTERY-ONLY POWER. DETAILS: DRIVING HOME FROM TOWN (ABOUT 10 MILES). CAR WAS BEHAVING NORMALLY, AND HAD BEEN DRIVEN APPROX 30 MILES EARLIER TODAY WI…
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SUMMARY: INTERNAL COMBUSTION ENGINE DIED WHILE DRIVING. LOTS OF INDICATOR LIGHTS ON DASH, AND MESSAGE APPEARED ON MULTIFUNCTION DISPLAY. WAS ABLE TO GET TO A SAFE LOCATION ON BATTERY-ONLY POWER. DETAILS: DRIVING HOME FROM TOWN (ABOUT 10 MILES). CAR WAS BEHAVING NORMALLY, AND HAD BEEN DRIVEN APPROX 30 MILES EARLIER TODAY WITH NO ISSUES. JUST BEFORE WE GOT HOME, THE FOLLOWING LIGHTS CAME ON (I RECORDED THEM EXACTLY): (1) RED TRIANGLE (MASTER WARNING LIGHT), (2) ENGINE CHECK (AMBER), (3) BRAKE SYSTEM WARNING (AMBER EXCLAMATION POINT IN PARENTHESES), (4) VSC, (5) HYBRID SYSTEM WARNING LIGHT (THIS WAS ALSO INDICATED ON THE LCD SCREEN). LCD HAD A MESSAGE ON IT WHICH I DID NOT RECORD EXACTLY (IT WAS SOMETHING GENERIC LIKE "THERE IS A PROBLEM"). THE INFO SCREEN WAS INDICATING THAT WE WERE RUNNING ON BATTERY ONLY, AND THE CAR HAD VERY LITTLE "PICKUP", BUT WE WERE ON OUR HOME STREET, WHICH IS QUITE STEEP. THE CAR HAS ABOUT 11000 MILES, AND DID SOMETHING SIMILAR WHEN WE FIRST GOT IT. AFTER TURNING THE CAR ON AND OFF A FEW TIMES, THE INTERNAL COMBUSTION ENGINE SEEMS TO WORK AGAIN, AND MOST OF THE INDICATORS HAVE NOW GONE OFF. (AMBER "ENGINE CHECK" IS STILL ON). AFTER ALL THIS HAPPENED, I GOT ONTO THE INTERNET TO SEE IF OTHERS HAD SEEN SIMILAR PROBLEMS, AND IT LOOKS LIKE THERE MAY BE A CLASS PROBLEM (I NOTE THERE HAVE BEEN A LARGE NUMBER OF THESE IN THE LAST FEW WEEKS - COULD IT BE TEMPERATURE-RELATED?) CAR WAS NOT OUT OF GAS (JUST REFILLED YESTERDAY) - GAS GUAGE SHOWING NEARLY FULL. VEHICLE WAS PURCHASED AUGUST 2004 (AFTER THE TSBS CAME OUT THAT IMPLICATED COMPUTER PROBLEMS), SO I'M SUSPECTING THIS MAY BE A DIFFERENT ISSUE THAN WAS DEALT WITH THERE. [XXX]. WILL NOTIFY TOYOTA TOMORROW AND REQUEST INSTRUCTIONS AS TO HOW TO PROCEED. *JS INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)
THIS IS NOT THE FIRST TIME THAT I HAVE HAD THIS PROBLEM, BUT I JUST LEARNED THIS IS THE VENUE TO STATE MY COMPLAINTS(I HAVE ANOTHER COMPLAINT ON THIS BOARD. I BOUGHT THIS CAR TO SAVE GAS,MONEY AND THE ENVIRONMENT,BUT NOW THIS CAR IS DOING NONE OF THESE FOR ME IN STOP AND GO TRAFFIC. WHILE I'M STUCK IN TRAFFIC IN DC(I395N), TH…
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THIS IS NOT THE FIRST TIME THAT I HAVE HAD THIS PROBLEM, BUT I JUST LEARNED THIS IS THE VENUE TO STATE MY COMPLAINTS(I HAVE ANOTHER COMPLAINT ON THIS BOARD. I BOUGHT THIS CAR TO SAVE GAS,MONEY AND THE ENVIRONMENT,BUT NOW THIS CAR IS DOING NONE OF THESE FOR ME IN STOP AND GO TRAFFIC. WHILE I'M STUCK IN TRAFFIC IN DC(I395N), THE BATTERY TAKES OVER. THE PROBLEM IS THE GAS DOESN'T KICK IN WHEN THE BATTERY IS LOW. I FIND THE BATTERY DOESN'T STAY CHARGED FOR OVER 28MINUTES WHILE MOVING IN TRAFFIC ABOUT 3 FEET EVERY 5 OR 10 MINUTES. I HAVE FIGURED OUT IN ORDER TO NOT GET STALLED (WHICH HAS HAPPENED TO ME, 2 TIMES ALREADY,BESIDES TODAY.) I HAVE TO HOLD THE BRAKE PEDAL DOWN WITH ONE FOOT AND REV THE GAS PEDAL WITH THE RIGHT FOOT IN ORDER TO CHARGE THE BATTERY AND NOT GET SLAMMED INTO FROM A VEHICLE BEHIND ME! MY WIFE REFUSES TO DRIVE THE CAR NOW FOR FEAR THAT SHE'LL STALL. I'M FILLING MY TANK MORE OFTEN NOW THAN WHEN I FIRST GOT THIS VEHICLE. DUE TO THE REVING OF THE VEHICLE WHICH WASTES MY GAS(SORTA DEFEATS THE PURPOSE OF BUYING A HYBRID FOR THE MOST PART!), ALSO THIS CAN'T BE GOOD FOR THE ENVIRONMENT EITHER! OH AND LETS NOT FORGET THE SAFETY FACTOR. I HAVE PEOPLE YELLING AT ME AND SAYING THEY WANT TO BUST MY A**! AND EVEN AN ELDERLY WOMAN WITH HANDICAP PLATES GAVE ME THE FINGER RIGHT AFTER SHE ALMOST SLAMMED INTO MY STALLED CAR. I'M EMBARRASSED AND SCARED TO DRIVE OVER 65 BECAUSE THE WAY THE CAR DIED ON ME 2 TIMES BEFORE.
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.
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.
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.
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
Official recalls
612V536000 · 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
3DP22005 · 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.
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