NHTSA owner reports · September 18, 2026 snapshot.
What owners actually said
197 reports6,000 miles · May 26, 2015
Vehicle Speed ControlCrash
TL* THE CONTACT OWNS A 2014 TOYOTA RAV4. WHILE DRIVING APPROXIMATELY 3 MPH AND MAKING A RIGHT TURN, THE VEHICLE ACCELERATED UNEXPECTEDLY AND CRASHED INTO A WOODED AREA. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THERE WERE NO INJURIES AND A POLICE REPORT WAS NOT FILED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE FAILURE MI…
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TL* THE CONTACT OWNS A 2014 TOYOTA RAV4. WHILE DRIVING APPROXIMATELY 3 MPH AND MAKING A RIGHT TURN, THE VEHICLE ACCELERATED UNEXPECTEDLY AND CRASHED INTO A WOODED AREA. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THERE WERE NO INJURIES AND A POLICE REPORT WAS NOT FILED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS 6,000.
NHTSA ODI #10721455
13,800 miles · May 7, 2015
Unknown Or Other
ON MAY 2, 2015, AT ABOUT 10:00 A.M. WE WERE DRIVING TO THE SCRANTON, PA, AREA. WE HAD JUST ENTERED THE ON-RAMP TO I-81 NORTH FROM RT. 309 WHEN WE HEARD A VERY LOUD BANG AND ROARING SOUND SIMILAR TO A DOOR ON A JET BLOWING OFF MID-AIR IN A MOVIE. THERE WAS NOTHING ON THE ROAD TO RUN OVER AND THE CLOSEST VEHICLE TO US WAS A TRUCK…
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ON MAY 2, 2015, AT ABOUT 10:00 A.M. WE WERE DRIVING TO THE SCRANTON, PA, AREA. WE HAD JUST ENTERED THE ON-RAMP TO I-81 NORTH FROM RT. 309 WHEN WE HEARD A VERY LOUD BANG AND ROARING SOUND SIMILAR TO A DOOR ON A JET BLOWING OFF MID-AIR IN A MOVIE. THERE WAS NOTHING ON THE ROAD TO RUN OVER AND THE CLOSEST VEHICLE TO US WAS A TRUCK TRACTOR AT LEAST 500 YARDS AHEAD OF US AND NOT DRIVING ON AN ANGLE THAT WOULD SEND ANYTHING AIRBORNE TO OUR AREA; NOR WERE WE NEAR AN UNDERPASSR. WE PUT OUR FLASHERS ON AND PULLED OVER AT THE FIRST SAFE AREA. UPON CHECKING OUR VEHICLE, WE DISCOVERED OUR SUNROOF GLASS HAD 'EXPLODED' WITH AN APPROXIMATE 8-10 INCH CIRCULAR HOLE DEAD CENTER AND THE REST OF THE GLASS FRACTURED. WE HAD THE INTERIOR SUNROOF COVERING PULLED CLOSED WHEN THIS OCCURRED. THE EDGES OF THE HOLE WERE BENT SLIGHTLY UPWARD INDICATING AN UPWARD FORCE. WE DIDN'T RUN OVER ANYTHING AND NOTHING STRUCK US, SO WE WERE FAIRLY SHOCKED. WE CHECKED OUR CELL PHONES AND DISCOVERED INDEPENDENCE TOYOTA, HAZELTON, PA, WAS ABOUT 5 MINUTES AWAY AT OUR NEXT EXIT. WE PULLED IN AND BOTH THE SALES PEOPLE AND SERVICE PEOPLE EXAMINED THE DAMAGE AND WERE AS SURPRISED AS US. NOTHING WAS FOUND IN THE GLASS DEBRIS THAT WOULD INDICATE SOMETHING STRUCK THE GLASS. INDEPENDENCE TOYOTA WAS GREAT BY CLEANING UP THE GLASS, PLACING TWO LAYERS OF HEAVY PLASTIC OVER THE SUNROOF OPENING AND TAPING IT SHUT. I AM A RETIRED POLICE LIEUTENANT. I KNOW WHAT IMPACT DAMAGE LOOKS LIKE AND THIS WAS NOT IT. UPON CHECKING ONLINE, THIS OCCURRENCE APPEARS MORE FREQUENTLY THAN ONE WOULD THINK IN VARIOUS MAKES OF VEHICLES. PRICE TOYOTA IN NEW CASTLE, DE IS DECLINING TO COVER THIS UNDER WARRANTY CITING THIS IS NORMAL GLASS BREAKAGE. I HAVE HAD WINDSHIELDS STRUCK BEFORE. THIS IS NOT REMOTELY CLOSE. IT IS NOT OKAY TO BE DRIVING YOUR VEHICLE AND SUDDENLY HAVE THE SUNROOF "EXPLODE" WITH NO CAUSING FACTORS PRESENT. *TR
NHTSA ODI #10715127
200 miles · Apr 16, 2015
Steering
THIS IS AN ONGOING INTERMITTENT PROBLEM. I NOTICE IT WHILE MOVING SLOWLY AND TURNING. THE STEERING HAS A SPOT WHERE IT IS HARDER TO TURN. IT FEELS LIKE THE POWER STEERING MOMENTARILY STALLS. I TOLD THE DEALERSHIP AT THE FIRST SERVICE APPOINTMENT AND THEY COULDN'T FIND ANYTHING. *TR
NHTSA ODI #10706096
10,000 miles · Apr 15, 2015
Visibility/wiper
WHY ARE THE WIPERS AND WINDSHIELD SO BAD, I CAN SEE BETTER IN THE RAIN WITH THE WIPERS OFF. THERE IS NO DIRT ON MY WINDSHIELD OR DEAD BUGS, I CLEANED THE WINDSHIELD IN MY GARAGE AND THEN DROVE IN THE RAIN TO PROVE A POINT. WHEN THE WIPERS ARE ON IT IS VERY HARD TO SEE BECAUSE OF THE BLURRING ON THE WINDSHIELD IT IS CLEARER JU…
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WHY ARE THE WIPERS AND WINDSHIELD SO BAD, I CAN SEE BETTER IN THE RAIN WITH THE WIPERS OFF. THERE IS NO DIRT ON MY WINDSHIELD OR DEAD BUGS, I CLEANED THE WINDSHIELD IN MY GARAGE AND THEN DROVE IN THE RAIN TO PROVE A POINT. WHEN THE WIPERS ARE ON IT IS VERY HARD TO SEE BECAUSE OF THE BLURRING ON THE WINDSHIELD IT IS CLEARER JUST LOOKING THROUGH THE RAIN. *TR
NHTSA ODI #10705833
3,500 miles · Jan 26, 2015
Service Brakes
NOISE WHEN BRAKING,AND PADS NOT RELEASING FROM ROTORS COMPLETELY. *TR
NHTSA ODI #10678971
2,400 miles · Jan 19, 2015
StructureInjury
THE BOTTOM OF ALL FOUR DOOR WHERE THE DOOR AT THE BOTTOM MEETS THE HARDEN RUBBER OR PLASTIC. LOOKING AT THE DOORS FROM THE OUTSIDE IT WOULD ALWAYS BE IN THE LOWER RIGHT CORNERS AT WHERE THE CURVED PART OF THE DOOR MEETS THE STRAIGHT PIECE RUNNING ALONG THE BOTTOM. EACH OF THESE CORNERS ARE EXTREMELY SHARP AND HAVE CAUSED UPON…
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THE BOTTOM OF ALL FOUR DOOR WHERE THE DOOR AT THE BOTTOM MEETS THE HARDEN RUBBER OR PLASTIC. LOOKING AT THE DOORS FROM THE OUTSIDE IT WOULD ALWAYS BE IN THE LOWER RIGHT CORNERS AT WHERE THE CURVED PART OF THE DOOR MEETS THE STRAIGHT PIECE RUNNING ALONG THE BOTTOM. EACH OF THESE CORNERS ARE EXTREMELY SHARP AND HAVE CAUSED UPON CLOSING BY WIND TO CUT THE CALF OF THE LED, WHICH LED TO OPENING TWO BLOOD VESSELS, REQUIRING EMERGENCY ATTENTION AND STITCHES. HAVE CHECKED AT LEAST 10 OTHER RAV4'S SAME MODELS SAME YEAR IN ADDITION TO FOUR ON TWO SEPARATE DEALER LOTS. ALL HAVE THE SAME ISSUE. *TR
NHTSA ODI #10676527
2,300 miles · Jan 19, 2015
Air BagsElectrical SystemService BrakesCrash
AT APPROXIMATELY 8:20 AM ON FRIDAY, JANUARY 16TH, 2015, I WAS PULLING INTO AN EMPTY PARKING SPOT IN FRONT OF MY APARTMENT COMPLEX AFTER DROPPING MY 6 YEAR-OLD AT SCHOOL. THIS WAS A ROUTINE AS I DO THIS EVERY MORNING. HOWEVER, AS I WAS SLOWING THE CAR DOWN PREPARING TO PARK (5-10 MPH), THE CAR SUDDENLY ACCELERATED (APPROXIMATELY …
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AT APPROXIMATELY 8:20 AM ON FRIDAY, JANUARY 16TH, 2015, I WAS PULLING INTO AN EMPTY PARKING SPOT IN FRONT OF MY APARTMENT COMPLEX AFTER DROPPING MY 6 YEAR-OLD AT SCHOOL. THIS WAS A ROUTINE AS I DO THIS EVERY MORNING. HOWEVER, AS I WAS SLOWING THE CAR DOWN PREPARING TO PARK (5-10 MPH), THE CAR SUDDENLY ACCELERATED (APPROXIMATELY 25-30 MPH) AND RAN OVER THE SIDEWALK, BUSHES AND INTO THE SIDE OF MY APARTMENT COMPLEX. DESPITE MY ATTEMPTS TO BRAKE, THE CAR WOULD NOT STOP. IN THE PROCESS I RAN THROUGH THE SIDE OF MY APARTMENT COMPLEX WALL AND FRONT GATE, NEARLY GOING RIGHT THROUGH MY FRONT DOOR AND LIVING ROOM WHERE MY 6 MONTH OLD AND WIFE WERE PLAYING. I HAD TO PLACE THE CAR IN PARK AND TURN THE CAR OFF. THAT STOPPED THE CAR. I THEN TURNED THE CAR BACK ON AND REVERSED. LUCKILY NO ONE WAS INJURED, BUT THERE WAS SUBSTANTIAL DAMAGE DONE TO THE SIDE OF MY APARTMENT COMPLEX AND MY VEHICLE. SHOULD BE NOTED, THAT DESPITE THE IMPACT, NO AIRBAGS WERE DEPLOYED. AT THE MOMENT, MY INSURANCE COMPANY HAS ME AT FAULT. I HAVE FILED WITH TOYOTA CORPORATE AND THEY ARE HAVING A SPECIALIST INVESTIGATE THE VEHICLE. I DO NOT FEEL SAFE IN THIS CAR. AND HOPE THAT THIS IS INVESTIGATED FURTHER. HAD I NOT TURNED OFF MY CAR, I WOULD HAVE SURELY GONE THROUGH MY FRONT DOOR AND INTO MY LIVING ROOM, POTENTIALLY HURTING MY 6 MONTH OLD AND WIFE. *TR
NHTSA ODI #10676497
5,000 miles · Nov 5, 2014
Electrical System
NEW RAV-4 WAS SLIGHTLY MORE THAN 1 MONTH OLD (7/1/14 TO 8/11/14). WE WERE DRIVING BACK TO ATLANTA FROM VACATION IN THE OUTER BANKS, WE WERE USING CRUISE CONTROL TO MAINTAIN SPEED ON THE EXPRESSWAY. WE CAME ACROSS A SLOWER MOVING TRUCK AND PULLED INTO THE PASSING LANE, STILL USING CRUISE CONTROL. WHILE PASSING SLOW TRUCK, AN…
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
NHTSA ODI #10652907
Mileage unknown · Oct 2, 2014
Air BagsSeatsStructureCrashInjury
ON BUSINESS AND VACATION, COMING FROM LA TO ATLANTA...I WAS DRIVING SPEED LIMIT IN FAR LEFT LANE, ON INTERSTATE, IN LAGRANGE ,GA, A TRUCK COMING ONTO THE INTERSTATE MERGING FROM FAR RIGHT LOSS CONTROL BECAUSE SHE WAS SPEEDING AND THE ROADS WERE SLICK FROM A LIGHT RAIN, SHE FISHTAILED FROM THE FAR RIGHT , CROSSING THE RIGHT LANE…
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ON BUSINESS AND VACATION, COMING FROM LA TO ATLANTA...I WAS DRIVING SPEED LIMIT IN FAR LEFT LANE, ON INTERSTATE, IN LAGRANGE ,GA, A TRUCK COMING ONTO THE INTERSTATE MERGING FROM FAR RIGHT LOSS CONTROL BECAUSE SHE WAS SPEEDING AND THE ROADS WERE SLICK FROM A LIGHT RAIN, SHE FISHTAILED FROM THE FAR RIGHT , CROSSING THE RIGHT LANE AND COMING HEAD ON IN OPPOSITE DIRECTION OF TRAFFIC , HITTING MY RENTAL VEHICLE..RAV 4. HIT US HEAD ON...THE AIRBAGS POPPED OUT EVERYWHERE, BLOCKING ESCAPE EXITS, WE THOUGHT THE TRUCK WOULD CATCH AFIRE, BECAUSE OF SMOKE SMELL, WE TRIED TO GET OUT, ALL DOORS ON THE LEFT OF THE VEHICLE WOULD NOT OPEN, ALTHOUGH IT WASN'T HIT IN ANY WAY, HAD TO CRAWL OVER SEATS AND UNDER AIRBAGS TO ESCAPE ON THE RIGHT SIDE OF VEHICLE. EVEN THE HATCH BACK DOOR AT REAR OF VEHICLE WOULD NOT OPEN AT ALL. WE JUST BARELY ESCAPED WITH OUR LIVES,AND INJURIES, BECAUSE IF WE DIDN'T PUSH THE RIGHT SIDE DOORS WE WOULD HAVE BEEN TRAPPED. *TR
NHTSA ODI #10640943
6,000 miles · Sep 10, 2014
Electrical SystemCrashFire
AFTER GETTING T-BONED AT AN INTERSECTION, MY TOYOTA RAV4 IMMEDIATELY CAUGHT FIRE. THE CAR WAS HIT ON THE PASSENGER SIDE BY THE RIGHT WHEEL AND RIGHT TO MID SECTION OF THE HOOD. WHEN I GOT OUT OF THE CAR IT WAS ALREADY ON FIRE. *TR
NHTSA ODI #10632313
Official recalls
4Nov 1, 2023
Toyota Motor Engineering & Manufacturing (Toyota) is recalling certain 2013-2018 RAV4 vehicles. Certain replacement 12-volt batteries may not fit properly in the battery tray, allowing the battery to move and contact the hold-down bracket, possibly causing a short circuit.
Consequence & remedy
Consequence: A battery short circuit increases the risk of a fire.
Remedy: Dealers will replace the battery clamp sub-assembly, battery tray, and positive terminal cover, free of charge. Owner letters were mailed December 27, 2024, to 2013-2014 RAV4 owners. Additional owner notification letters will be mailed in phases, phase 2 will begin on May 14, 2025, and phase 3 in late July 2025. Owners may contact Toyota's customer service at 1-800-331-4331. Toyota's numbers for this recall are 23TB13 and 23TA13.
Mar 13, 2015
Toyota Motor Engineering & Manufacturing (Toyota) is recalling certain model year 2015 Camry, Camry Hybrid, Highlander, and Highlander Hybrid, and 2014-2015 Rav4 vehicles. A component of the electric power steering (EPS) electronic control unit (ECU) may have been damaged during the manufacturing process. Over time, this damage may result in failure of the electric power steering system.
Consequence & remedy
Consequence: An unexpected loss of power steering increases the risk of a crash.
Remedy: Toyota will notify owners, and dealers will inspect the serial number of the EPS ECU or steering column assembly. If the number is within the affected range, the EPS ECU will be replaced, free of charge. The recall began on May 7, 2015. Owners may contact Toyota customer service at 1-800-331-4331.
Jan 16, 2015
Southeast Toyota Distributors, LLC (SET) is recalling certain model year 2013-2015 Toyota Rav4 vehicles manufactured June 1, 2013, to December 29, 2014, and equipped with an accessory trailer light module. The software within the module may incorrectly detect an electrical short and preventively turn off the electrical current and the trailer lights.
Consequence & remedy
Consequence: If the system incorrectly detects an electrical short and turns off the trailer lights while the trailer is being towed at night, there is an increased risk of a crash.
Remedy: SET will notify owners, and dealers will replace the trailer light module with a new unit with corrected software, free of charge. The recall began on March 17, 2015. Owners may contact SET customer service at 1-866-405-4226. SET's number for this recall is SET-15A.
Additional source detail variants (2)
Trailer Hitches
Southeast Toyota Distributors, LLC (SET) is recalling certain model year 2013-2015 Toyota Rav4 vehicles manufactured June 1, 2013, to December 29, 2014, and equipped with an accessory trailer light module. The software within the module may incorrectly detect an electrical short and preventively turn off the electrical current and the trailer lights.
Consequence: If the system incorrectly detects an electrical short and turns off the trailer lights while the trailer is being towed at night, there is an increased risk of a crash.
Remedy: SET will notify owners, and dealers will replace the trailer light module with a new unit with corrected software, free of charge. The recall began on March 17, 2015. Owners may contact SET customer service at 1-866-405-4226. SET's number for this recall is SET-15A.
Exterior Lighting
Southeast Toyota Distributors, LLC (SET) is recalling certain model year 2013-2015 Toyota Rav4 vehicles manufactured June 1, 2013, to December 29, 2014, and equipped with an accessory trailer light module. The software within the module may incorrectly detect an electrical short and preventively turn off the electrical current and the trailer lights.
Consequence: If the system incorrectly detects an electrical short and turns off the trailer lights while the trailer is being towed at night, there is an increased risk of a crash.
Remedy: SET will notify owners, and dealers will replace the trailer light module with a new unit with corrected software, free of charge. The recall began on March 17, 2015. Owners may contact SET customer service at 1-866-405-4226. SET's number for this recall is SET-15A.
Dec 30, 2014
Southeast Toyota Distributors, LLC (SET) is recalling certain model year 2014-2015 Toyota 4Runner, Tacoma, FJ Cruiser, Land Cruiser, RAV4, Scion FRS, and XB vehicles. The affected vehicles may have accessories installed by SET, such as running boards or other items, that were incorrectly installed. The accessory attaching fasteners were not tightened with the proper torque, possibly causing the accessory to detach from the vehicle.
Consequence & remedy
Consequence: Accessories that detach from a vehicle may result in a vehicle crash and/or personal injury.
Remedy: SET will notify owners, and dealers will inspect and tighten the affected bolts, free of charge. The recall began February 23, 2015. Owners may contact SET customer service at 1-866-405-4226. SET's number for this recall is SET-14B.
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
1PE21005 · Battery Hold Down Bracket Thermal Events
Opened Feb 25, 2021 · Closed Aug 12, 2024
Status: closed (inferred from source dates) · Electrical SYSTEM:12V/24V/48V Battery
The Office of Defects Investigation (ODI) opened a Preliminary Evaluation (PE) to understand the contributing factors and frequency of vehicle fires originating from the battery region of the engine compartment in Model Year (MY) 2013-2018 Toyota RAV4 vehicles on 25 February 2021. At the time of opening, ODI attributed eleven allegations and additional EWR events to this PE. PE21005 focused on replacement batteries installed in the subject vehicles. No reported fire event identified in PE21005 involved the originally supplied 12V battery. The reported fires took place in vehicles known to contain aftermarket batteries or whose age exceeded the expected life of the original equipment battery. ODI identified battery dimensioning as it relates to the battery retention system (hold down bracket, radiator support bolt, J-hook, and battery tray) as the main factor set in the contact between the battery hold down bracket contacting the positive terminal of the 12V battery. The subject vehicles carried over the same battery tray and retention system from the prior generation (MY2006 – MY2012) of RAV4 vehicles. However, the subject vehicles were equipped with a dimensionally smaller battery (Group 35) than the prior generation (Group 24F). The smaller- length measurement in the Group 35 battery size in a battery tray originally designed to fit a Group 24F battery contributed to increased potential for battery movement which was exacerbated by the diversity in aftermarket battery configuration and irregularities intrinsic to battery replacement procedures. Battery movement coupled with the proximity of the B+ terminal on the battery and the grounded electrically conductive hold down bracket set the stage for a short to ground leading to an engine stall (if in operation) followed by a vehicle fire. This investigation was not able to classify the installation status, battery size, or cause of every allegation due to the fire event causing damage to the area, inaccessible vehicle, modification to the battery retention system after the event, and/or inconclusive photographic evidence. Toyota's investigation of the issue identified aftermarket battery catalogs that listed an improper battery replacement size (Group 26R) that would nevertheless fit into the subject vehicles whose battery retention system is incapable of reliably restraining a Group 26R battery. On 18 November 2021, Toyota initiated a consumer advisory campaign (21TG01) to the subject vehicle owners, notifying them of the correct size battery and offering a free inspection of the battery and retention hardware, a caution label to affix to the hold down bracket, and a discounted replacement 12V battery. This investigation with Toyota established three broad categories to characterize the battery retention system state of a given vehicle: "correct", "minor mis-installation", and "major mis-installation". - The "correct" terminology references the front bolt, bracket, and J-hook installed in a position not in contact with the positive battery terminal and the front bolt torqued to 17 Nm and the J-hook engaged with the tray hole and torqued to 4.9 Nm. - A "minor mis-installation" would describe the three retention components installed in the prescribed location, however not to the correct torque values. - The "major mis-installation" condition would constitute a retention component missing or disconnected from the system. Toyota's own testing used five exemplar batteries installed on a subject vehicle in each battery categorization resulted in: - Contact between the B+ terminal and hold down bracket in "major mis-installations" - Movement of the battery in "minor mis-installations" - No observable motion in "correct" installations. ODI conducted its own evaluation of the Toyota- specified replacement battery and 5 aftermarket Group 35 batteries. The six batteries tested conformed to the Group 35 Battery Council International (BCI) standard on overall dimensional tolerance and terminal location. That standard does not define the edge shape or material of battery casing. Physical interaction between the hold down bracket and the battery case and the friction between the casing material and the battery tray resulted in a large variability in movement forces required to incite movement when the battery was installed in the "correct" condition. Resulting in movement at an induced lateral load between 0.6 G and 1.91 G equivalent force across each battery. This force is higher than a typical vehicle could exert in a steady state turn and would only experience loads through brief shock or impulses. Multiple shock or impulse loads across time would contribute to a delay between the replacement battery installation and the fire event. Likelihood of a fire event increases as the installation method degraded from the "correct", to "minor mis-installation", and then to "major mis-installation". Protruding vent caps atop some of the batteries tested aided in restricting battery movement relative to the hold down. An absence of vent caps permitted additional movement. Following several discussions and vehicle inspections with ODI during this investigation, on 01 November 2023, Toyota filed a safety recall (NHTSA 23V-734) of 1,853,568 MY 2013 through MY 2018 Toyota RAV4 vehicles to reduce the risk of a vehicle fire with redesigned battery retention components. To review the ODI reports cited in the Closing Resume ODI Report Identification Number document, go to NHTSA.gov.
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