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2016 Toyota RAV4

Owner reports · Recalls · Investigations

Similar to other model years

Owner complaints for the 2016 Toyota RAV4 do not stand out strongly from the model-year median of 258.5.

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When problems were reported

Mileage at the reported incident

151 reports with mileage · 88 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.

  • Electrical System. Review the 59 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Service Brakes. Review the 44 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Exterior Lighting. Review the 28 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →

NHTSA owner reports · September 18, 2026 snapshot.

33 crash reports12 fire reports21 injury reports

Electrical System complaints

59 reports
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102,000 miles · May 6, 2021
Electrical SystemEngineFire

OUR 2016 RAV4 PRODUCED A LOUD CLUNK THEN LOST POWER (AFTER BEING DRIVE 5-10 MINUTES) AND CAME TO A COMPLETE STOP. THE ENGINE WOULD NOT TURN OVER NOR THE CAR POWER COME BACK ON. WHITE SMOKE BEGAN WITHIN 30 SECONDS OF LOSING POWER AND WITHIN ONE MINUTE FLAMES BEGAN SHOOTING OUT UNDER THE DRIVER'S SIDE UPPER HOOD.

NHTSA ODI #11415425

52,000 miles · Apr 30, 2021
Electrical SystemFireInjury

TL* THE CONTACT OWNS A 2016 TOYOTA RAV4. THE CONTACT STATED THAT WHILE HER HUSBAND WAS STOPPED AT A TRAFFIC LIGHT, HE STARTED SMELLING AN ABNORMAL BURNING ODOR BEFORE FLAMES STARTED COMING UP FROM UNDER THE DASHBOARD AND OUT OF THE DRIVER'S AND PASSENGER'S SIDE VENTS. THE DRIVER PULLED OVER AND STARTED POURING WATER FROM A COOLE…

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TL* THE CONTACT OWNS A 2016 TOYOTA RAV4. THE CONTACT STATED THAT WHILE HER HUSBAND WAS STOPPED AT A TRAFFIC LIGHT, HE STARTED SMELLING AN ABNORMAL BURNING ODOR BEFORE FLAMES STARTED COMING UP FROM UNDER THE DASHBOARD AND OUT OF THE DRIVER'S AND PASSENGER'S SIDE VENTS. THE DRIVER PULLED OVER AND STARTED POURING WATER FROM A COOLER ONTO THE FIRE TO TRY TO EXTINGUISH THE FLAMES HOWEVER, THE FLAMES REIGNITED. ANOTHER MOTORIST PULLED OVER TO ASSIST AND DISCONNECTED THE BATTERY. A BUSINESS OWNER ALSO STOPPED BY, AND EXTINGUISHED THE FLAMES WITH A FIRE EXTINGUISHER. THE FIRE DEPARTMENT ARRIVED HOWEVER, THE FIRE WAS ALREADY EXTINGUISHED. A POLICE REPORT WAS FILED. THE DRIVER STATED THAT A FIRE REPORT WAS NOT FILED. THE CONTACT STATED THAT THE DASHBOARD WAS DESTROYED. THE DRIVER SUSTAINED BURNS ON BOTH HANDS HOWEVER, MEDICAL ATTENTION WAS NOT SOUGHT. THE DRIVER CONTACTED FIESTA KIA (7400 LOMAS BLVD NE, ALBUQUERQUE, NM 87110, (505)999-2700) WHERE THE VEHICLE HAD BEEN PURCHASED ONLY 22 DAYS EARLIER. THE DEALER ARRIVED AT THE SCENE AND THE VEHICLE WAS TOWED TO THE DEALER WHERE IT REMAINED STILL UNREPAIRED. THE INSURANCE PROVIDER WAS CONTACTED AND INFORMED THE DRIVER THAT A FIRE INVESTIGATOR WOULD BE SENT OUT TO INSPECT THE VEHICLE, WHICH WAS STILL PENDING. THE VEHICLE WAS NOT REPAIRED. THE INSURANCE PROVIDER HAD NOT YET DECIDED WHETHER OR NOT THE VEHICLE WAS A TOTAL LOSS. THE MANUFACTURER WAS NOT CONTACTED OR INFORMED OF THE FAILURE. THE FAILURE MILEAGE WAS 52,000.

NHTSA ODI #11414617

39,000 miles · Mar 16, 2021
Electrical SystemExterior Lighting

TL* THE CONTACT OWNS A 2016 TOYOTA RAV4. THE CONTACT STATED THAT THE KEY FOB FAILED TO START THE VEHCILE. ADDITIONALLY, THE REAR BRAKE LIGHTS WERE FILLED WITH WATER AND WERE INOPERABLE. THE CONTACT CALLED NYC MOTORCARS OF THE BRONX (3748 BOSTON RD, THE BRONX, NY 10469, (347) 966-4272) HOWEVER, THE VEHICLE WAS NOT DIAGNOSED NOR R…

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TL* THE CONTACT OWNS A 2016 TOYOTA RAV4. THE CONTACT STATED THAT THE KEY FOB FAILED TO START THE VEHCILE. ADDITIONALLY, THE REAR BRAKE LIGHTS WERE FILLED WITH WATER AND WERE INOPERABLE. THE CONTACT CALLED NYC MOTORCARS OF THE BRONX (3748 BOSTON RD, THE BRONX, NY 10469, (347) 966-4272) HOWEVER, THE VEHICLE WAS NOT DIAGNOSED NOR REPAIRED. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 39,000.

NHTSA ODI #11403332

63,500 miles · Mar 10, 2021
Electrical SystemUnknown Or Other

THE NAVIGATION DISPLAYS, RADIO AND ALL EQUIPMENT THAT USES IT QUITS AND SHUTS DOWN AND WILL GO OFF AND ON 3-8 TIMES AND THEN IT SEEMS TO BE OK. I WAS DRIVING THE VEHICLE DOWN THE HIGHWAY WHEN IT HAPPENS. THIS HAS HAPPEN MANY TIMES.

NHTSA ODI #11400257

85,000 miles · Mar 9, 2021
Electrical SystemSteeringUnknown Or Other

WHILE DRIVING ON A LOCAL ROAD I STARTED TO LOSE ELECTRICAL POWER. AT FIRST I LOST POWER STEERING AND SHORTLY AFTER THE HEAT STOPPED WORKING AND ALL THE LIGHTS ON THE DASHBOARD LIT UP. WHEN I BROUGHT THE CAR TO BE DIAGNOSED THE FUSE BOX HAD BEEN BURNED AND WIRES MELTED AND THERE WAS SMOKE INDICATING THERE HAD BEEN A FIRE AROUND T…

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WHILE DRIVING ON A LOCAL ROAD I STARTED TO LOSE ELECTRICAL POWER. AT FIRST I LOST POWER STEERING AND SHORTLY AFTER THE HEAT STOPPED WORKING AND ALL THE LIGHTS ON THE DASHBOARD LIT UP. WHEN I BROUGHT THE CAR TO BE DIAGNOSED THE FUSE BOX HAD BEEN BURNED AND WIRES MELTED AND THERE WAS SMOKE INDICATING THERE HAD BEEN A FIRE AROUND THE FUSE/ELECTRICAL AREA

NHTSA ODI #11399953

30,000 miles · Mar 9, 2021
Electrical SystemVisibility/wiper

I HAVE HAD AND CONTINUE TO HAVE BATTERY TROUBLE WITH MY TOYOTA RAV4. I FIRST BOUGHT A NEW 2014 AND AT MY REGULAR MAINTENANCE AT THE DEALERSHIP, THE BATTERY WAS REPLACED SEVERAL TIMES. I WAS UNCOMFORTABLE ENOUGH TO TRADE IT IN AND GET A NEW 2016. I STILL HAVE THIS ONE, BUT IT CONTINUES TO HAVE BATTERY TROUBLE. I HAVE BEEN LEFT ST…

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I HAVE HAD AND CONTINUE TO HAVE BATTERY TROUBLE WITH MY TOYOTA RAV4. I FIRST BOUGHT A NEW 2014 AND AT MY REGULAR MAINTENANCE AT THE DEALERSHIP, THE BATTERY WAS REPLACED SEVERAL TIMES. I WAS UNCOMFORTABLE ENOUGH TO TRADE IT IN AND GET A NEW 2016. I STILL HAVE THIS ONE, BUT IT CONTINUES TO HAVE BATTERY TROUBLE. I HAVE BEEN LEFT STRANDED AT WORK WHEN MY CAR WOULD NOT START. THAT IS WHEN I FOUND MASSIVE AMOUNTS OF CORROSION, AND TO THIS DAY, THE TERMINALS CORRODE OVER EVEN WITH NEW BATTERY. THE PASSENGER DOOR DOES NOT ALWAYS LOCK WITH THE KEY BUTTON BC OF THIS ISSUE. I WOULD ESTIMATE I'VE REPLACED THE BATTERY 3-5 TIMES BETWEEN THE TWO CARS, WITH NO REAL SOLUTION. BATTERIES HAVE ALWAYS BEEN REPLACED/INSTALLED BY THE LOCAL TOYOTA DEALERSHIP. (I'M SURE INVOICES COULD BE PULLED IF NECESSARY) MY CARS HAVE NOT STALLED WHILE RUNNING, THEY WON'T START OR JUST START TO HAVE ELECTRICAL ISSUES W LIGHTS, AND IT GETS CHECKED BY THE DEALERSHIP. THEY USUALLY RECOMMEND REPLACEMENT WHILE THE BATTERY IS COVERED. A SEPARATE BUT EQUALLY UNSETTLING ISSUE IS WITH THE WINDSHIELD. IT RECENTLY CRACKED DUE TO A PASSENGER FLICKING A BUG ON IT. YOU WOULD THINK A ROCK LANDED ON IT.

NHTSA ODI #11399862

44,156 miles · Mar 2, 2021
Electrical SystemFire

TL* THE CONTACT OWNED A 2016 TOYOTA RAV4. WHILE HER HUSBAND WAS MAKING A RIGHT TURN AT 30 MPH, THE VEHICLE ABRUPTLY SHUT OFF WITHOUT WARNING; HOWEVER, HER HUSBAND WAS ABLE TO RESTART THE VEHICLE UPON DEPRESSION OF THE ACCELERATOR PEDAL. AS THEY CONTINUED TO DRIVE, THE FAILURE OCCURRED TWO MORE TIMES AND AFTER THE THIRD FAILURE, …

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TL* THE CONTACT OWNED A 2016 TOYOTA RAV4. WHILE HER HUSBAND WAS MAKING A RIGHT TURN AT 30 MPH, THE VEHICLE ABRUPTLY SHUT OFF WITHOUT WARNING; HOWEVER, HER HUSBAND WAS ABLE TO RESTART THE VEHICLE UPON DEPRESSION OF THE ACCELERATOR PEDAL. AS THEY CONTINUED TO DRIVE, THE FAILURE OCCURRED TWO MORE TIMES AND AFTER THE THIRD FAILURE, A BLACKISH SMOKE BEGAN TO EMIT FROM UNDERNEATH THE FRONT PASSENGER SIDE OF THE HOOD. THE CONTACT'S HUSBAND WAS ABLE TO EXIT THE VEHICLE AND EXTINGUISH THE FIRE WITH A WATER BOTTLE. THE AUTHORITIES WERE CALLED TO THE SCENE, AND THE FIRE DEPARTMENT REMOVED THE BATTERY FROM THE VEHICLE. A FIRE AND POLICE REPORT WERE FILED; NO INJURIES WERE REPORTED. DUE TO THE FAILURE, THE VEHICLE WAS TOWED TO SHEEHY TOYOTA OF STAFFORD(95 GARRISONVILLE RD, STAFFORD, VA 22554) WHERE THEY INITIALLY GAVE THE CONTACT AN ESTIMATE TO REPLACE THE VEHICLE PARTS IN ORDER TO CHECK IF THE VEHICLE WAS STILL OPERABLE. DUE TO THE HIGH COST OF THE REPAIR, HER INSURANCE COMPANY DEEMED THE VEHICLE TOTAL LOSS AND WAS DESTROYED. THE MANUFACTURER HAD YET TO BE NOTIFIED OF THE FAILURE. THE VEHICLE HAD BEEN DESTROYED. THE FAILURE MILEAGE WAS 44,156. *BF THE CONSUMER PROVIDED THE REPORT FROM THE FIRE DEPARTMENT.

NHTSA ODI #11398767

75,000 miles · Feb 19, 2020
Electrical System

REAR HATCH MOTOR FAILED. HATCH WILL NOT OPEN. TOYOTA ADMITS FAULT/DEFECT, BUT REFUSES TO COVER COSTS ASSOCIATED WITH FIXING IT.

NHTSA ODI #11310180

6,145 miles · Jan 6, 2020
Electrical SystemEngineSteering

THE WIRING HARNESS WAS CHEW COMPLETELY UP. THIS AFFECTED MY POWER BRAKES, ENGINE,STEERING SYSTEM, ETC. THESE LIGHTS CAME ON WHILE DRIVING THE CAR! RATS CHEWED MY WIRING .

NHTSA ODI #11297434

Mileage unknown · Dec 23, 2019
Electrical System

MY CAR PHONE DOES NOT WORK WITH MY IPHONE 11 PRO MAX. I HAVE A 2016 TOYOTA RAV4 HYBRID. THE BLUETOOTH ON MY NEW PHONE WELL NOT PAIR WITH MY ETUNE SOFTWARE. TBE PHONE CAN'T EVEN DISCOVER IT. WHEN IT FINALLY FAILS MY SCREEN ON MY CAT PHONE SAYS NO MICROPHONE DETECTED. ROTORS SAYS IT'S AN APPLE SOFTWARE PROBLEM. JUS A SAFETY ISSUE…

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MY CAR PHONE DOES NOT WORK WITH MY IPHONE 11 PRO MAX. I HAVE A 2016 TOYOTA RAV4 HYBRID. THE BLUETOOTH ON MY NEW PHONE WELL NOT PAIR WITH MY ETUNE SOFTWARE. TBE PHONE CAN'T EVEN DISCOVER IT. WHEN IT FINALLY FAILS MY SCREEN ON MY CAT PHONE SAYS NO MICROPHONE DETECTED. ROTORS SAYS IT'S AN APPLE SOFTWARE PROBLEM. JUS A SAFETY ISSUE. I DRIVE AND WORK OUT OF MY CAR SIX DAYS A WEEK.

NHTSA ODI #11290997

Official recalls

3

23V734000 · Electrical SYSTEM:12V/24V/48V Battery

Nov 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.

16V236000 · Equipment:other:labels; Tires

Apr 22, 2016

Southeast Toyota Distributors, LLC (SET) is recalling certain model year 2016 Toyota Yaris, Rav4, Land Cruiser and 4Runner vehicles, and Scion FR-S, iM, and TC vehicles manufactured January 28, 2016, to March 14, 2016. The Load Carrying Capacity Modification Label may not reflect the correct added weight of the installed accessories. As a result, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard number 110, "Tire Selection and Rims for Passenger Cars."

Consequence & remedy

Consequence: An incorrect label may result in the vehicle being overloaded, increasing the risk of a crash.

Remedy: SET will notify owners, and provide them a corrected label to be installed over the inaccurate label, free of charge. The recall began on June 3, 2016. Owners may contact SET customer service at 1-866-405-4226. SET's number for this recall is SET16A.

Additional source detail variants (2)

Equipment:other:labels

Southeast Toyota Distributors, LLC (SET) is recalling certain model year 2016 Toyota Yaris, Rav4, Land Cruiser and 4Runner vehicles, and Scion FR-S, iM, and TC vehicles manufactured January 28, 2016, to March 14, 2016. The Load Carrying Capacity Modification Label may not reflect the correct added weight of the installed accessories. As a result, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard number 110, "Tire Selection and Rims for Passenger Cars."

Consequence: An incorrect label may result in the vehicle being overloaded, increasing the risk of a crash.

Remedy: SET will notify owners, and provide them a corrected label to be installed over the inaccurate label, free of charge. The recall began on June 3, 2016. Owners may contact SET customer service at 1-866-405-4226. SET's number for this recall is SET16A.

Tires

Southeast Toyota Distributors, LLC (SET) is recalling certain model year 2016 Toyota Yaris, Rav4, Land Cruiser and 4Runner vehicles, and Scion FR-S, iM, and TC vehicles manufactured January 28, 2016, to March 14, 2016. The Load Carrying Capacity Modification Label may not reflect the correct added weight of the installed accessories. As a result, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard number 110, "Tire Selection and Rims for Passenger Cars."

Consequence: An incorrect label may result in the vehicle being overloaded, increasing the risk of a crash.

Remedy: SET will notify owners, and provide them a corrected label to be installed over the inaccurate label, free of charge. The recall began on June 3, 2016. Owners may contact SET customer service at 1-866-405-4226. SET's number for this recall is SET16A.

16V198000 · Electronic Stability Control (esc); Service Brakes, Hydraulic:antilock/traction Control/electronic Limited Slip

Apr 7, 2016

Toyota Motor Engineering & Manufacturing (Toyota) is recalling certain model year 2016 Toyota RAV4 vehicles manufactured October 30, 2015, to February 3, 2016, 2016 Lexus RX350 vehicles manufactured October 26, 2015, to February 8, 2016, and 2016 Lexus ES350 vehicles manufactured September 1, 2015, to February 29, 2016. These vehicles are equipped with an ABS actuator that may have a damaged O-ring which could result in improper brake fluid pressure control during ABS, Traction Control, or Stability Control activation. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard (FMVSS) number 126, "Electronic Stability Control Systems."

Consequence & remedy

Consequence: Insufficient brake fluid pressure may cause a loss of vehicle control, increasing the risk of a crash.

Remedy: Toyota will notify owners, and dealers will inspect the brake actuator, replacing it as necessary, free of charge. The recall began on May 4, 2016, 2016. Owners may contact Toyota customer service at 1-800-331-4331. Toyota's number for this recall is G0I, GLC.

Additional source detail variants (2)

Electronic Stability Control (esc)

Toyota Motor Engineering & Manufacturing (Toyota) is recalling certain model year 2016 Toyota RAV4 vehicles manufactured October 30, 2015, to February 3, 2016, 2016 Lexus RX350 vehicles manufactured October 26, 2015, to February 8, 2016, and 2016 Lexus ES350 vehicles manufactured September 1, 2015, to February 29, 2016. These vehicles are equipped with an ABS actuator that may have a damaged O-ring which could result in improper brake fluid pressure control during ABS, Traction Control, or Stability Control activation. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard (FMVSS) number 126, "Electronic Stability Control Systems."

Consequence: Insufficient brake fluid pressure may cause a loss of vehicle control, increasing the risk of a crash.

Remedy: Toyota will notify owners, and dealers will inspect the brake actuator, replacing it as necessary, free of charge. The recall began on May 4, 2016, 2016. Owners may contact Toyota customer service at 1-800-331-4331. Toyota's number for this recall is G0I, GLC.

Service Brakes, Hydraulic:antilock/traction Control/electronic Limited Slip

Toyota Motor Engineering & Manufacturing (Toyota) is recalling certain model year 2016 Toyota RAV4 vehicles manufactured October 30, 2015, to February 3, 2016, 2016 Lexus RX350 vehicles manufactured October 26, 2015, to February 8, 2016, and 2016 Lexus ES350 vehicles manufactured September 1, 2015, to February 29, 2016. These vehicles are equipped with an ABS actuator that may have a damaged O-ring which could result in improper brake fluid pressure control during ABS, Traction Control, or Stability Control activation. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard (FMVSS) number 126, "Electronic Stability Control Systems."

Consequence: Insufficient brake fluid pressure may cause a loss of vehicle control, increasing the risk of a crash.

Remedy: Toyota will notify owners, and dealers will inspect the brake actuator, replacing it as necessary, free of charge. The recall began on May 4, 2016, 2016. Owners may contact Toyota customer service at 1-800-331-4331. Toyota's number for this recall is G0I, GLC.

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

1

PE21005 · 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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