2021 Toyota RAV4 Prime

We have COMPLETELY lost brakes on MULTIPLE occasions for a few seconds per occasion. Brake loss has occurred upon slow, even braking and on flat, dry, even pavement with no pot poles or loose gravel around. When this happens, an orange light appears on the dash, we lose brakes for a few seconds, the car regains brakes, and jolts forward with no change in foot position on the brake pedal. We have taken the car to the dealer multiple times and every single time this incident has occurred the rear right wheel speed shows about a 10% variation in speed compared to all the other wheels per the vehicle diagnostic report/record of behavior. The orange light we are seeing on the dash is the ABS light. There is no feedback in the brake pedal on any occasion. This incident has occurred about 20 times so far. Our car is available for inspection. The dealer believes this is being caused by a software issue and not a faulty sensor. This car is a danger to us and anyone around us as we have needed to swerve into the shoulder multiple times to avoid hitting someone ahead of us. This NEEDS to be fixed before it injures or kills someone. This issue has still been persistent even after taking care of the VSC recall and a reset/recalibration to the braking system. We have taken the car to the dealer for this issue on: 4/4/22, 4/15/22, 4/25/22, 5/11/22, 6/4/22. *We have been limiting our driving in this car due to the issue happening multiple times a week, that is why there hasn't been many trips to the dealer much between May and June. I want to reiterate, this doesn't sound like a defect per the dealer, it sounds like a software issue!

Today, May 28, 2022, between 11:40am and 11:45am, I was making a left at an intersection when the vehicle did not respond to my pressing of the gas pedal input. It was highly dangerous and the oncoming traffic had to slow down not to hit me. The car, which usually responds very well to my pressing the gas pedal has not responded now for a 2nd time. This is the first time I am reporting because I am realizing this is not anomalous and highly concerning as it puts my family at immediate risk of getting into an accident. Please note that I have reached out to the dealer to report his issue, however, I am not sure how to proceed should this become a continued issue down the road. My vehicle is a 2021 Toyota RAV4 Prime XSE model.

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.

Vehicle abruptly and harshly slowed from 65mph to around 30 on the highway and multiple error lights and messages came up. After initial deceleration the vehicle seemed to drive normally. Once in a safe place to stop the vehicle was shut off and the only errors remained had been check engine and hybrid system malfunction and again the vehicle seemed to drive normally and was brought to the dealership for inspection the next day on its own power. Errors seen in dash and Head Unit: brake power low, brake support system malfunction, check engine, hybrid system malfunction, park sensor malfunction, lane trace assist malfunction, sonar malfunction, headlight system malfunction. Dealership states they need to contact Toyota as there is something wrong and they are unsure what it is at this time.

On March 19, 2022 I was attempting to make a left turn onto a five lane (including the center left turn lane) road. When the traffic cleared my car (a plug-in hybrid in EV mode) did not accelerate as it usually does, but slowly rolled into the first lane of traffic. I pushed the accelerator to the floor but it stopped in the traffic lane. I had to quickly select reverse and back out of the first lane of oncoming traffic. Luckily the car behind me had not moved up and I had room to avoid an accident. This seemed like it may have been a failure of the collision avoidance system. Our safety was definitely at risk as the oncoming traffic was moving at 40-45 mph. The problem has not occurred since and the Toyota dealer was unable to confirm or reproduce. My wife was also in the car and can verify what happened. There were no other warnings, messages or symptoms. In the three photos, the first shows the 2 motorcycles I intended to get behind when I completed my turn. The next two photos show how I needed to back up to clear the lane for oncoming traffic. I do have a 30 second video of the entire incident.

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.

There is an issue with Toyota's Rav4 Prime fuel tank gauge incorrectly reading fuel left in the tank or prematurely stopping gasoline to fill the tank. My car is available for inspection upon request. No safety impact. Dealer confirmed issue by testing my car but says this is "working as intended". The fueling problem is consistent and not intermittent and started immediately after using my first tank of gas. Even when low fuel warning light is on, I am unable to fully fill the tank to the advertised 14.5 gallons. Inability to fill the fuel tank impacts the vehicle’s total available driving distance and forces me to make more frequent stops at the gas station. This issue could very well be due to the same design defect in the 2019-2021 Toyota Rav4 Hybrid class action lawsuit in which Toyota has admitted fault and settled the class action.