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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

What owners actually said

239 reports
Mileage unknown · Nov 20, 2020
Unknown Or Other

PLEASE BE AWARE THAT NEWER TOYOTA CAR AND TRUCK MODELS ARE NOT COMPATIBLE FOR THE MOST PART, WITH THE LATEST TO SERIES OF APPLE IPHONES, THE 11 AND THE JUST RELEASED 12 SERIES. THIS HAS BEEN A KNOWN ISSUE FOR OVER A YEAR, YET NO RESOLUTION HAS BEEN PROVIDED. THIS IS A POTENTIAL SAFETY HAZARD ESPECIALLY IN STATES THAT REQUIRE HA…

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PLEASE BE AWARE THAT NEWER TOYOTA CAR AND TRUCK MODELS ARE NOT COMPATIBLE FOR THE MOST PART, WITH THE LATEST TO SERIES OF APPLE IPHONES, THE 11 AND THE JUST RELEASED 12 SERIES. THIS HAS BEEN A KNOWN ISSUE FOR OVER A YEAR, YET NO RESOLUTION HAS BEEN PROVIDED. THIS IS A POTENTIAL SAFETY HAZARD ESPECIALLY IN STATES THAT REQUIRE HANDS FREE USE OF A CELL PHONE WHILE OPERATING A VEHICLE. HOW CAN TWO LARGE COMPANIES NOT WORK TOGETHER TO PROVIDE THE NECESSARY INTEGRATION BETWEEN THEIR PRODUCTS TO ALLOW SAFE OPERATION OF THEIR VEHICLES AND PHONE. I ASK TO NHTSA TO INVESTIGATE THIS MATTER AND TAKE PROPER ACTIONS TO MITIGATE THIS RISK ASAP.

NHTSA ODI #11375487

40,132 miles · Oct 29, 2020
Service BrakesCrash

TL* THE CONTACT OWNS A 2016 TOYOTA RAV4. THE CONTACT STATED THAT WHILE HER HUSBAND WAS DRIVING 65 MPH AND APPROACHING AN EXIT OFF THE FREEWAY RAMP, THE CONTACT DEPRESSED THE BRAKE PEDAL WHICH FAILED TO ENGAGE PROPERLY AS THE BRAKE PEDAL TRAVELED TO THE FLOORBOARD. THE CONTACTS HUSBAND PUMPED THE BRAKE PEDAL A COUPLE OF TIMES BUT…

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TL* THE CONTACT OWNS A 2016 TOYOTA RAV4. THE CONTACT STATED THAT WHILE HER HUSBAND WAS DRIVING 65 MPH AND APPROACHING AN EXIT OFF THE FREEWAY RAMP, THE CONTACT DEPRESSED THE BRAKE PEDAL WHICH FAILED TO ENGAGE PROPERLY AS THE BRAKE PEDAL TRAVELED TO THE FLOORBOARD. THE CONTACTS HUSBAND PUMPED THE BRAKE PEDAL A COUPLE OF TIMES BUT FAILED TO RESPOND CAUSING THE VEHICLE TO CROSSOVER A 4 LANE HIGHWAY, ONTO A UPHILL ONRAMP WHERE IT CAME TO A STOP AFTER CRASHING INTO A CURB. THE VEHICLE WAS RESTARTED AND THE VEHICLE RESUMED TO NORMAL. THE VEHICLE RECEIVED MINOR DAMAGE TO THE PASSENGER FRONT TIRE, AND THE RIM WAS CRACKED. THE VEHICLE WAS TOWED TO A DEALER (BALISE TOYOTA 1399 RIVERDALE ST, WEST SPRINGFIELD, MA 01089 (413) 306-3037) HOWEVER THE VEHICLE WAS NOT DIAGNOSED OR SEEN. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE AND INFORMED THE CONTACT THAT A TECHNICIAN WOULD GO OUT TO THE DEALER AND INSPECTED THE VEHICLE RECORDERS WHICH DETERMINED NO FAULTY CODES. THE FAILURE MILEAGE WAS APPROXIMATELY 40,132.

NHTSA ODI #11367043

19,000 miles · Oct 16, 2020
Structure

TL* THE CONTACT OWNS A 2016 TOYOTA RAV4. THE CONTACT STATED THAT HE NOTICED MOISTURE COMING FROM THE FLOOR ON THE FRONT PASSENGER'S SIDE OF THE VEHICLE. THE CONDITION WAS NOTICEABLE AFTER IT RAINED OR WHEN THE AIR CONDITIONER WAS BEING USED. THE VEHICLE WAS TAKEN TO THE DEALER LONGO TOYOTA 3534 N. PECK RD., EL MONTE, CA 91731, (…

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TL* THE CONTACT OWNS A 2016 TOYOTA RAV4. THE CONTACT STATED THAT HE NOTICED MOISTURE COMING FROM THE FLOOR ON THE FRONT PASSENGER'S SIDE OF THE VEHICLE. THE CONDITION WAS NOTICEABLE AFTER IT RAINED OR WHEN THE AIR CONDITIONER WAS BEING USED. THE VEHICLE WAS TAKEN TO THE DEALER LONGO TOYOTA 3534 N. PECK RD., EL MONTE, CA 91731, (626) 539-2403. THE MECHANIC WAS UNABLE DIAGNOSE THE ISSUE SINCE THE FLOOR AREA WAS DRIED. IT WAS SUGGESTED TO THE CONTACT TO BRING THE VEHICLE BACK ANOTHER TIME. THE VEHICLE WAS RETURNED TO THE DEALER AND DIAGNOSED THAT THE AIR CONDITIONING DRAIN HOSE UNDERNEATH THE FLOOR WAS CLOGGED WITH SPIDER WEBBING. THE FLOOR UNDERNEATH THE CARPET WAS COVERED IN MOLD AND MILDEW DUE TO THE MOISTURE. THE CONTACT WAS CONCERNED ABOUT A HEALTH RISK FROM THE MOLD AND MILDEW. THE DEALER QUOTED A REPAIR COST OF $4,000 TO $5,000. THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS 19,000.

NHTSA ODI #11364685

40,000 miles · Aug 26, 2020
Service BrakesCrash

TL* THE CONTACT OWNS A 2016 TOYOTA RAV4. THE CONTACT STATED THAT THE BRAKE SYSTEM FAILED. THE CONTACT STATED WHEN THE DRIVER DROVE AT 60 MPH, THE VEHICLE IN FRONT MADE A SUDDEN STOP AND WHEN THE DRIVER ENGAGED THE BRAKE PEDAL IT WENT TO THE FLOOR BOARD AND CAUSED THE DRIVER TO CRASH INTO THE TRUCK'S REAR END. THE CONTACT STATED …

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TL* THE CONTACT OWNS A 2016 TOYOTA RAV4. THE CONTACT STATED THAT THE BRAKE SYSTEM FAILED. THE CONTACT STATED WHEN THE DRIVER DROVE AT 60 MPH, THE VEHICLE IN FRONT MADE A SUDDEN STOP AND WHEN THE DRIVER ENGAGED THE BRAKE PEDAL IT WENT TO THE FLOOR BOARD AND CAUSED THE DRIVER TO CRASH INTO THE TRUCK'S REAR END. THE CONTACT STATED THAT THE VEHICLE WAS TAKEN TO AN UNKNOWN DEALER FOR INSPECTION. HOWEVER, THE DEALER TEST DROVE THE VEHICLE AND WAS UNABLE TO DUPLICATE THE FAILURE. THE CONTACT ALSO WANTED TO ADVISE THAT THE BRAKE PADS WAS PREVIOUSLY REPLACED BY AN UNKNOWN DEALER BECAUSE THE CONTACT HAD NOTICED THAT TOOK A LONGER TIME FOR THE BRAKE TO ENGAGE WHEN THE VEHICLE WAS DRIVEN OVER 60 MPH. THERE WERE NO INJURIES TO REPORT. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOT CONTACTED. THE FAILURE MILEAGE WAS 40,000.

NHTSA ODI #11351453

11,000 miles · Aug 14, 2020
Unknown Or Other

ALL FOUR DOOR LOCKS HAVE MALFUNCTIONED. EACH HAVE BEEN REPLACED. NOW THE REPLACEMENTS ARE ALSO FAILING. THE DOORS DO NOT LOCK OR UNLOCK WITH THE KEY FOB. MAKING IT IMPOSSIBLE TO GET INTO THE CAR WHEN I START THE CAR, THE DOORS ARE SUPPOSED TO LOCK AUTOMATICALLY, WHICH DOES NOT HAPPEN. MAKING IT INCREDIBLY UNSAFE ALL OF THE INF…

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ALL FOUR DOOR LOCKS HAVE MALFUNCTIONED. EACH HAVE BEEN REPLACED. NOW THE REPLACEMENTS ARE ALSO FAILING. THE DOORS DO NOT LOCK OR UNLOCK WITH THE KEY FOB. MAKING IT IMPOSSIBLE TO GET INTO THE CAR WHEN I START THE CAR, THE DOORS ARE SUPPOSED TO LOCK AUTOMATICALLY, WHICH DOES NOT HAPPEN. MAKING IT INCREDIBLY UNSAFE ALL OF THE INFORMATION IS AT NORTH HOLLYWOOD TOYOTA IT HAS BEEN GOING ON SINCE 2018.

NHTSA ODI #11349228

Mileage unknown · Aug 13, 2020
Service Brakes, Hydraulic

TL* THE CONTACT OWNS A 2016 TOYOTA RAV4. THE CONTACT STATED THAT WHILE DRIVING AND TAPPING ON THE BRAKE PEDAL TO SLOW THE VEHICLE, THE FRONT-END VIBRATED ABNORMALLY. THE VEHICLE WAS TAKEN TO THE KOONS FORD OF BALTIMORE DEALER LOCATED AT 6970 SECURITY BLVD, WOODLAWN, MD 21244, WHERE THE BRAKE PADS AND BRAKE ROTORS WERE REPLACED. …

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TL* THE CONTACT OWNS A 2016 TOYOTA RAV4. THE CONTACT STATED THAT WHILE DRIVING AND TAPPING ON THE BRAKE PEDAL TO SLOW THE VEHICLE, THE FRONT-END VIBRATED ABNORMALLY. THE VEHICLE WAS TAKEN TO THE KOONS FORD OF BALTIMORE DEALER LOCATED AT 6970 SECURITY BLVD, WOODLAWN, MD 21244, WHERE THE BRAKE PADS AND BRAKE ROTORS WERE REPLACED. THE FAILURE RECURRED AND THE VEHICLE VIBRATED MUCH HARDER AND WAS TAKEN BACK TO THE SAME DEALER WHO THEN REPLACED A PIECE OF RUBBER AROUND THE BRAKE PEDAL. THE FAILURE RECURRED. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS NOT PROVIDED.

NHTSA ODI #11349000

25,000 miles · Jul 25, 2020
Unknown Or Other

I WAS DRIVING ON A CITY STREET AND I HEARD A LOUD CRACKING SOUND. MY SUNROOF CRACKED AND THE GLASS SHATTERED. I WAS NOT UNDER ANY SORT OF UNDERPASS OR TREE.

NHTSA ODI #11341454

53,000 miles · Jul 13, 2020
Unknown Or Other

NEW APPLE IPHONE 11PROMAX. NO LONGER CAN GET HANDS FREE TEXTING SO SAFETY COMPROMISED. STATIONARY ,IN MOTION ALL ROADS

NHTSA ODI #11339178

130,000 miles · Jul 8, 2020
Power Train

TL* THE CONTACT OWNS A 2016 TOYOTA RAV4. THE CONTACT STATED THAT WHILE DRIVING AT VARIOUS SPEEDS, BETWEEN 2,000-3,000 RPM, THE VEHICLE JOLTED BACKWARD AND STALLED WITHOUT WARNING. THE VEHICLE SHUDDERED AND THE BRAKE PEDAL WAS DEPRESSED TO REGAIN CONTROL OF THE VEHICLE. THE CONTACT TOOK THE VEHICLE TO JACK TAYLOR'S ALEXANDRIA TOY…

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TL* THE CONTACT OWNS A 2016 TOYOTA RAV4. THE CONTACT STATED THAT WHILE DRIVING AT VARIOUS SPEEDS, BETWEEN 2,000-3,000 RPM, THE VEHICLE JOLTED BACKWARD AND STALLED WITHOUT WARNING. THE VEHICLE SHUDDERED AND THE BRAKE PEDAL WAS DEPRESSED TO REGAIN CONTROL OF THE VEHICLE. THE CONTACT TOOK THE VEHICLE TO JACK TAYLOR'S ALEXANDRIA TOYOTA (3750 RICHMOND HWY, ALEXANDRIA, VA 22305) WHERE A DIAGNOSTIC TEST WAS PERFORMED. THE CONTACT WAS INFORMED THAT THE DEFECT WAS RELATED TO THE TORQUE CONVERTER. THE CONTACT WAS INFORMED THAT THE TORQUE CONVERTER NEEDED TO BE REPLACED, AND WAS GIVEN AN ESTIMATE FOR THE REPAIR. THE MANUFACTURER HAD YET TO BE NOTIFIED OF THE FAILURE. THE VEHICLE HAD YET TO BE REPAIRED. THE FAILURE MILEAGE WAS 130,000.

NHTSA ODI #11338271

Mileage unknown · May 14, 2020
Visibility/wiper

WINDSHIELD WIPER INTERVALS DO NOT CHANGE SPEED AND THE FASTEST SETTING IS INADEQUATE IN HEAVY RAIN. *TR

NHTSA ODI #11324567

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.

Go deeper into Toyota RAV4 problems