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2018 Toyota RAV4

Owner reports · Recalls · Investigations

Similar to other model years

Owner complaints for the 2018 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

144 reports with mileage · 187 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 129 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Engine. Review the 32 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Service Brakes. 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.

31 crash reports32 fire reports13 injury reports

Exterior Lighting complaints

23 reports
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14,000 miles · Mar 11, 2019
Exterior Lighting

REPEATEDLY, WHILE IN MOTION, WITH THE HEADLIGHTS IN THE "AUTO" MODE, AND THE "AUTOMATIC HIGH BEAM FEATURE ENABLED (WHICH SWITCHES THE HEADLIGHTS FROM HIGH BEAM TO LOW BEAM AUTOMATICALLY BASED ON THE PRESENCE OF ONCOMING HEADLIGHTS/TAIL LIGHTS AHEAD/AMBIENT LIGHT LEVELS) THE AUTO HIGHBEAM FEATURE WILL DISABLE ITSELF, GENERALLY TI…

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REPEATEDLY, WHILE IN MOTION, WITH THE HEADLIGHTS IN THE "AUTO" MODE, AND THE "AUTOMATIC HIGH BEAM FEATURE ENABLED (WHICH SWITCHES THE HEADLIGHTS FROM HIGH BEAM TO LOW BEAM AUTOMATICALLY BASED ON THE PRESENCE OF ONCOMING HEADLIGHTS/TAIL LIGHTS AHEAD/AMBIENT LIGHT LEVELS) THE AUTO HIGHBEAM FEATURE WILL DISABLE ITSELF, GENERALLY TIED TO THE PASSING OF A CAR WITH BRIGHT LIGHTS. WHEN THIS FEATURE DISABLES ITSELF IT PREVENTS ALL USE OF HIGHBEAMS. THE ONLY WAY TO GET HIGHBEAMS WHILE THE FEATURE IS "DISABLED" (EVEN IN COMPLETE DARKNESS) IS TO "ROTATE" THE STALK CONTROL AWAY FROM "AUTO HEADLIGHT" TO "MANUAL HEADLIGHT". THE FEATURE EVENTUALLY RE-ENABLES ITSELF, BUT USUALLY TAKES A NUMBER OF MINUTES, LEAVING ME WITHOUT THE SAFETY OF HIGHBEAMS FOR THAT PERIOD, UNLESS I GO THROUGH THE CUMBERSOME ACT OF TURNING HEADLAMPS TO "MANUAL". THIS IS PARTICULARLY DANGEROUS DURING MY COMMUTE WHERE I DRIVE A NUMBER OF MILES ON UNLIT STATE ROADS. I RELY ON HIGHBEAMS TO ALERT ME TO THE PRESENCE OF DEER AND OTHER ANIMALS CROSSING THE ROAD WHICH OCCURS ROUTINELY. NOT HAVING HIGHBEAMS FOR A NUMBER OF MILES EXPOSES ME TO THE RISK OF NOT SEEING THESE HAZARDS IN TIME TO REACT PROPERLY. IN ADDITION, HAVING TO DIVERT MY ATTENTION TO WHETHER THIS FEATURE HAS DISABLED ITSELF AND TAKING MANUAL ACTION TO CIRCUMVENT THE ISSUE IS A DISTRACTION WHILE MY FOCUS SHOULD BE ON POSSIBLE HAZARDS. I HAVE REPORTED THE ISSUE TO TOYOTA. CASE NUMBER [XXX] HAS BEEN ASSIGNED. A TOYOTA CASE MANAGER CONTACTED ME AND STATED THAT SHE EXPERIENCES THE VERY SAME ISSUE WITH HER 2018 RAV4 BUT THERE ARE NO FIXES IDENTIFIED BY TOYOTA FOR THE ISSUE, SO THEREFORE THERE IS NOTHING SHE OR THE DEALER CAN DO. I STRONGLY FEEL THIS IS A SAFETY ISSUE IN THAT THERE IS A RISK THAT AN ACCIDENT WILL OCCUR, POSSIBLY THE STRIKING OF A PEDESTRIAN, DUE TO POOR VISIBILITY OR DISTRACTION TRYING TO OVERRIDE THE FEATURE WHILE DRIVING. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6). *TT

NHTSA ODI #11185930

11,000 miles · Mar 1, 2019
Exterior Lighting

I HAVE A NEW XLE AND THE HEADLIGHTS ARE DANGEROUS. THESE ARE PROJECTOR HEADLIGHTS THAT CAST A VERY FOCUSED BEAM FORWARD. IT IS FRIGTENING WHEN YOU DRIVE IN SOME ROADS WITHOUT A LOT OF AMBIENT LIGHT. WITH THE LOW BEAMS ON, IT IS LIKE SOMEONE PAINTED THE TOP HALF OF MY WINDSHIELD BLACK. THERE IS LITTLE PERIPHERAL ILLUMINATION, SO …

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I HAVE A NEW XLE AND THE HEADLIGHTS ARE DANGEROUS. THESE ARE PROJECTOR HEADLIGHTS THAT CAST A VERY FOCUSED BEAM FORWARD. IT IS FRIGTENING WHEN YOU DRIVE IN SOME ROADS WITHOUT A LOT OF AMBIENT LIGHT. WITH THE LOW BEAMS ON, IT IS LIKE SOMEONE PAINTED THE TOP HALF OF MY WINDSHIELD BLACK. THERE IS LITTLE PERIPHERAL ILLUMINATION, SO I CAN SEE WHAT IS DIRECTLY IN FRONT OF ME, AND NOTHING ELSE. WHERE THE ROAD INCLINES DOWN, THE ILLUMINATION CUTS OUT JUST A FEW FEET OFF THE GROUND, BELOW THE LEVEL OF THINGS LIKE STOP SIGNS. THERE IS ABSOLUTELY NO PERIPHERAL ILLUMINATION RIGHT AT THE FRONT OF THE CAR, SO WHEN I TURN, I CAN'T SEE WHAT I'M TURNING INTO UNTIL IT'S DIRECTLY IN FRONT OF MY CAR, LIKE PEDESTRIANS. TO MAKE MATTERS WORSE, THE DEALERSHIP TOLD ME NOT TO USE LED BULBS, BECAUSE IT COULD CAUSE ELECTRICAL ISSUES WITH THE CAR.

NHTSA ODI #11183530

Mileage unknown · Jan 13, 2019
Exterior Lighting

THE AUTO HIGH BEAM FEATURE HAS BEEN CHOOSING TO DISENGAGE AND TURN ITSELF OFF AT RANDOM. THERE ARE ALSO TIMES THAT AT NIGHT, UPON START-UP, THE AUTO HIGH BEAM SYSTEM WILL REFUSE TO ENGAGE (LIGHT SWITCH TURNED TO AUTO AND STALK PUSHED FORWARD, DRIVING OVER 25 MPH).

NHTSA ODI #11166720

4,200 miles · Nov 27, 2018
Exterior Lighting

TL* THE CONTACT OWNS A 2018 TOYOTA RAV4. WHILE DRIVING AT NIGHT OR AFTER DUSK, THE HEADLAMPS PROVIDED INSUFFICIENT ILLUMINATION TO OPERATE THE VEHICLE SAFELY. THE CONTACT WAS CONCERNED THAT THE FAILURE WAS DUE TO A FEATURE ON THE VEHICLE WHERE THE HEADLIGHTS DIM WHEN APPROACHING ONCOMING TRAFFIC. THE VEHICLE WAS TAKEN TO UEBELHO…

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TL* THE CONTACT OWNS A 2018 TOYOTA RAV4. WHILE DRIVING AT NIGHT OR AFTER DUSK, THE HEADLAMPS PROVIDED INSUFFICIENT ILLUMINATION TO OPERATE THE VEHICLE SAFELY. THE CONTACT WAS CONCERNED THAT THE FAILURE WAS DUE TO A FEATURE ON THE VEHICLE WHERE THE HEADLIGHTS DIM WHEN APPROACHING ONCOMING TRAFFIC. THE VEHICLE WAS TAKEN TO UEBELHOR TOYOTA (LOCATED AT 788 W 12TH AVE, JASPER, IN 47546, (812) 482-2222) TO BE DIAGNOSED AND THEY STATED THAT THE VEHICLE PERFORMED AS INTENDED. ADDITIONALLY, THE CONTACT STATED THAT THE ILLUMINATION WAS INADEQUATE IN RURAL AREAS, BUT WAS NOT AFFECTED IN AN URBAN SETTING. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE ISSUE. THE APPROXIMATE FAILURE MILEAGE WAS 4,200.

NHTSA ODI #11154187

Mileage unknown · Oct 26, 2018
Exterior Lighting

BRAND NEW RECENTLY PURCHASED VEHICLE AND THERE IS CONDENSATION IN BOTH HEAD LIGHTS

NHTSA ODI #11143024

7,000 miles · Oct 3, 2018
Exterior Lighting

TL* THE CONTACT OWNS A 2018 TOYOTA RAV4. THE CONTACT COMPLAINED ABOUT A DESIGN FLAW WITH THE VEHICLE. WHILE DRIVING IN THE FOG, THE LOW BEAM HEADLIGHTS REFLECTED LIGHT BACK, WHICH BLINDED THE DRIVER AND MADE IT IMPOSSIBLE TO SEE AT NIGHT. THE VEHICLE WAS TAKEN TO TOYOTA OF POWAY (858-486-2900, LOCATED AT 13631 POWAY RD, POWAY, C…

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TL* THE CONTACT OWNS A 2018 TOYOTA RAV4. THE CONTACT COMPLAINED ABOUT A DESIGN FLAW WITH THE VEHICLE. WHILE DRIVING IN THE FOG, THE LOW BEAM HEADLIGHTS REFLECTED LIGHT BACK, WHICH BLINDED THE DRIVER AND MADE IT IMPOSSIBLE TO SEE AT NIGHT. THE VEHICLE WAS TAKEN TO TOYOTA OF POWAY (858-486-2900, LOCATED AT 13631 POWAY RD, POWAY, CA 92064) WHERE THE LIGHTS WERE CHECKED. THE TECHNICIAN STATED THAT NO ADJUSTMENT WAS NEEDED AND THAT THE VEHICLE WAS PERFORMING AS DESIGNED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE AND STATED THAT THERE WAS NO RECALL. THE FAILURE WAS NOT REMEDIED. THE FAILURE MILEAGE WAS APPROXIMATELY 7,000.

NHTSA ODI #11133116

2,000 miles · Sep 28, 2018
Exterior Lighting

MY 2018 RAV4 IS EQUIPPED WITH DYNAMIC RADAR CRUISE CONTROL, A FEATURE WHICH I LIKE VERY MUCH LIKE WHEN TRAVELING ON INTERSTATE HIGHWAYS. THIS FEATURE AUTOMATICALLY DECELERATES MY VEHICLE TO MATCH THE SPEED OF THE VEHICLE AHEAD AND KEEPS YOU FOLLOWING AT A SAFE DISTANCE. HOWEVER, THE SAFETY ISSUE I HAVE DISCOVERED IS THAT WHEN …

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MY 2018 RAV4 IS EQUIPPED WITH DYNAMIC RADAR CRUISE CONTROL, A FEATURE WHICH I LIKE VERY MUCH LIKE WHEN TRAVELING ON INTERSTATE HIGHWAYS. THIS FEATURE AUTOMATICALLY DECELERATES MY VEHICLE TO MATCH THE SPEED OF THE VEHICLE AHEAD AND KEEPS YOU FOLLOWING AT A SAFE DISTANCE. HOWEVER, THE SAFETY ISSUE I HAVE DISCOVERED IS THAT WHEN THE VEHICLE AUTOMATICALLY DECELERATES, IT APPARENTLY DOES NOT ACTIVATE THE BRAKE LIGHTS AND THE VEHICLE BEHIND YOU IS NOT WARNED THAT YOU ARE SLOWING DOWN. TWICE IN THE FIRST COUPLE MONTHS OF OWNING THIS VEHICLE, WHILE TRAVELING ON RELATIVELY STRAIGHT, FLAT, INTERSTATE HIGHWAYS, I HAD THE DYNAMIC RADAR CRUISE CONTROL ENGAGED AND THE VEHICLE IN FRONT OF ME REDUCED SPEED FAIRLY QUICKLY (FROM APPROXIMATELY 65 TO 45MPH) DUE TO ROAD CONSTRUCTION. MY VEHICLE AUTOMATICALLY SLOWED ACCORDINGLY, BUT THE VEHICLE BEHIND ME DID NOT REALIZE I WAS SLOWING DOWN BECAUSE MY BRAKE LIGHTS DID NOT ACTIVATE AND I WAS VERY NEARLY REAR ENDED. FORTUNATELY, SERIOUS ACCIDENTS WERE NARROWLY AVOIDED IN BOTH THESE INCIDENTS. I BELIEVE THE DYNAMIC RADAR CRUISE CONTROL FEATURE IS VERY GOOD, VERY USEFUL FEATURE; HOWEVER, THE SYSTEM MUST BE MODIFIED TO ACTIVATE THE BRAKE LIGHTS WHEN THE VEHICLE AUTOMATICALLY DECELERATES. ONE OF THE INCIDENTS OCCURRED IN JULY, 2018, AND THE OTHER IN AUGUST, 2018. I HAVE DISCUSSED THE ISSUE WITH OUR LOCAL TOYOTA DEALER AND ALSO WITH THE TOYOTA CUSTOMER EXPERIENCE CENTER (800 331-4331). THE LATTER ESTABLISHED A CASE NUMBER (1809280901). I WISH TO ENSURE APPROPRIATE FOLLOW-UP OCCURS TO CORRECT THIS SAFETY ISSUE.

NHTSA ODI #11132193

50 miles · Sep 25, 2018
Exterior LightingVisibility/wiper

PURCHASED 2018 RAV 4 ADVENTURE THREE DAY'S AGO AND IT IS IMPOSSIBLE TO DRIVE AT NIGHT ON A ROAD WITH NO OTHER AVAILABLE LIGHTING. EXTREMELY DANGEROUS. IT APPEARS AS THOUGH A VEIL COVERS 1/2 TO 2/3 OF WINDSHIELD MAKING VISIBILITY NEARLY IMPOSSIBLE. THE BEAM ANGLE OF THE HEADLIGHTS BARELY COVER THE ROAD IN FRONT OF YOU AND NOTH…

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PURCHASED 2018 RAV 4 ADVENTURE THREE DAY'S AGO AND IT IS IMPOSSIBLE TO DRIVE AT NIGHT ON A ROAD WITH NO OTHER AVAILABLE LIGHTING. EXTREMELY DANGEROUS. IT APPEARS AS THOUGH A VEIL COVERS 1/2 TO 2/3 OF WINDSHIELD MAKING VISIBILITY NEARLY IMPOSSIBLE. THE BEAM ANGLE OF THE HEADLIGHTS BARELY COVER THE ROAD IN FRONT OF YOU AND NOTHING ABOVE THE HEIGHT OF THE VEHICLE HOOD. YOU CAN SEE NOTHING IN FRONT OF YOU AND EVEN LESS ON THE SIDES OF THE ROAD.CHANGING THE SETTING FROM AUTO, ON AND HIGH BEAM TO NOT CHANGE RESULT. I WANT TO RETURN THE VEHICLE. THERE IS NO POINT IN HAVING A VEHICLE YOU CAN ONLY DRIVE DURING THE DAY. EXTREMELY DANGEROUS AND VERY DISAPPOINTING! I HOPE NO ONE SUFFERS INJURY OR DEATH AS A RESULT OF THIS POOR DESIGN.

NHTSA ODI #11131151

500 miles · Sep 24, 2018
Exterior Lighting

MY RAV4 HAS VERY POOR LIGHTING AT NIGHT MAKING IT HARD TO SEE THE LINES ON THE ROAD. I JUST BOUGHT THIS VEHICLE NEW A FEW DAYS AGO BUT THE DEALERSHIP SAYS THAT THEY CANNOT FIND ANY DEFECTS WITH THE HEAD LIGHT BUT DOES AGREE THE LIGHT OUTPUT IS POOR.

NHTSA ODI #11130873

Mileage unknown · Aug 13, 2018
Exterior Lighting

DANGEROUS TO DRIVE AT NIGHT DUE TO PROJECTOR HEADLIGHTS BEAM PATTERN CUTOFF. WHILE DRIVING WITH LOW BEAM HEADLIGHTS ON AT NIGHT, TOP PART OF LIGHT BEAM PATTERN IS A STRAIGHT LINE LEFT TO RIGHT ACROSS FIELD OF VISION WITH ZERO LIIGHT ABOVE MIDPOINT FIELD OF VISION BOTTOM (ROAD) TO TOP (SKY). ESPECIALLY DANGEROUS WHEN DECENDING HI…

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DANGEROUS TO DRIVE AT NIGHT DUE TO PROJECTOR HEADLIGHTS BEAM PATTERN CUTOFF. WHILE DRIVING WITH LOW BEAM HEADLIGHTS ON AT NIGHT, TOP PART OF LIGHT BEAM PATTERN IS A STRAIGHT LINE LEFT TO RIGHT ACROSS FIELD OF VISION WITH ZERO LIIGHT ABOVE MIDPOINT FIELD OF VISION BOTTOM (ROAD) TO TOP (SKY). ESPECIALLY DANGEROUS WHEN DECENDING HILLS IN DARK AND ROAD AHEAD IS FLAT (OR HORIZONTAL) AS WELL AS DECENDING A DIP WHICH CLIMBS BACK UP. NOWHERE NEAR ENOUGH LIGHT ABOVE MID FIELD OF VISION. REQUIRES HIGHBEAMS SELECTED WHICH CANNOT ALWAYS BE SELECTED DUE TO ONCOMING TRAFFIC OR FOLLOWING SOMEONE WHERE IT WOULD BLIND THEM. HIGHER MODEL RAV4 TRIM LEVELS HAVE LED HEADLIGHTS WHICH TOYOA SHOULD RETROFIT ONTO XLE, LE, AND ANY OTHER MODELS AFFECTED. WORRIED ABOUT WIFE DRIVING WITH KIDS. 6 MONTHS INTO A 3YR LEASE.

NHTSA ODI #11119755

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.

19V503000 · Equipment:other:labels

Jun 28, 2019

Southeast Toyota Distributors, LLC (SET) is recalling certain 2017-2019 Toyota Camry, Corolla, Rav4, Sienna, and Yaris iA vehicles equipped with factory-installed floor mats. The load carrying capacity modification label may be incorrect. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard (FMVSS) number 110, "Tire Selection and Rims."

Consequence & remedy

Consequence: An incorrect label may lead to unintentionally overloading the vehicle, increasing the risk of a crash.

Remedy: SET will notify owners and provide a corrected label for placement over the inaccurate label, free of charge. The recall began August 23, 2019. Owners may contact Toyota customer service at 1-888-270-9371. SET's number for this recall is SET19A.

17V831000 · Equipment:other:labels

Dec 20, 2017

Toyota Motor Engineering & Manufacturing (Toyota) is recalling certain 2017-2018 Toyota 4Runner and Tundra, 2018 Toyota Highlander, RAV4 and Lexus GX460 and 2017 Toyota Sienna and Tacoma vehicles. These vehicles may have incorrect load carrying capacity modification labels. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard (FMVSS) number 110, "Tire Selection and Rims."

Consequence & remedy

Consequence: An incorrect load information label can result in the operator overloading the vehicle and increasing the risk of a crash.

Remedy: Toyota will notify owners and provide them with corrected labels, free of charge. The recall began on January 23, 2018. Owners may contact Toyota customer service at 1-800-331-4331. Toyota's numbers for this recall are H0Z for Toyota vehicles, and HLF for Lexus vehicles.

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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