2021 Toyota RAV4 Prime

All four brake rotors are defective, the metal is pitted scored and not smooth, as it should be. This increases the braking distance. The vehicle is equipped with regenerative braking thus increasing the brake service interval. With mileage at 21600 this is not normal. Upon inspection at the dealer, it was described as normal for this type of vehicle. I pointed out several vehicle in the service area as what the rotors should appear. (I have had three Chevy Volts with similar drivetrain and never had to replace rotors or brake pads.) I will upload photos of the rotors and dealers comments.

My RAV4 PRIME was in stop and go traffic. Brakes did not switch from regen braking to physical brakes. Slammed on the brakes several times, they did not slow the car enough. Eventually the brakes locked up as the RAV4 rear ended the car in front. Pushing that car into the one in front of it, and that one in front of that, and that one in front of that. Causing damage to three other cars. Two other people are claiming medical, the driver went to the ER. Air bags did not deploy. Taking to the repair shop. They were shocked that the air bags didn't go off given the the condition of the frame. Toyota Motor North America (TMNA) did an inspection to read the event data recorder (EDR). Brake were applied at -1.5 seconds before impact. And here is the weird part, saying that the ABS activated then too. There was no notification, and the brakes locked up. Speed went from 46 to 21.1 mph. This occurred at 3,573 miles on only a few month old RAV4. I'm well aware of what ABS feels like when it goes off.

While exiting an interstate and applying the brakes, the vehicle struck a small bump (pot-hole) in the roadway with the front passenger wheel. The car lurched forward and stopped slowing down. The brakes had disengaged on all wheels. After approximately 2 seconds, the car started braking again and I was able to regain control and stop. This momentary loss of braking ability could have caused me to rear end the vehicle in front had I not left excess room. The loss of brakes increased the braking distance required and could lead to the loss of control if the roadway is slick. I have been able to reproduce this issue. No ABS or TCS lights illuminated. No beeps or other warning messages materialized. The car is available for inspection upon request. It appears to be an issue with the regenerative brakes switching over to the mechanical brakes when the car believes there is wheel slip.

While braking there is a brief release, which I believe happens when car switches from regenerative to friction braking. It feels like I have taken my foot off the brake for a moment, but I have not. Result is car briefly stops braking, which can cause loss of control. Has happened consistently for months, less pronounced with hard vs soft braking

I AM EXPERIENCING INCONSISTENT BRAKE FEEL AFTER ABS ACTUATION DURING SLOW AND STEADY APPLICATION OF THE BRAKES ON ROUGH OR SLICK ROAD SURFACES. STOPPING DISTANCES ARE INCREASED COMPARED WITH MY EXPECTATION FOR A GIVEN PEDAL FORCE. PLEASE NOTE THAT THE 2010 TOYOTA PRIUS HAD A SIMILAR ISSUE, AND A RECALL WAS ISSUED UNDER NHTSA CAMPAIGN 10V039000.