2021 Toyota RAV4

Dear NHTSA Office of Defects Investigation, I am writing to formally report a safety concern with my 2021 Toyota RAV4 XSE Hybrid regarding its fuel tank capacity and refueling issue. Despite the advertised fuel tank capacity of approximately 14.5 gallons, my vehicle only allows me to fill around 9 gallons before the pump automatically shuts off. This significantly reduces my driving range and forces me to refuel much more frequently than expected. After researching, I discovered that Toyota issued Technical Service Bulletin T-SB-0109-20 acknowledging this issue, along with Customer Support Program 20TE04. However, my local Toyota dealership refuses to acknowledge the issue or perform the necessary repairs, despite my vehicle clearly experiencing the problem. I believe this poses a safety risk because: •The incorrect fuel level readings can lead to drivers miscalculating available fuel, potentially resulting in unexpected stalls or breakdowns. •It suggests a defect in the fuel tank design, which Toyota has acknowledged but has not proactively addressed with a recall. •Many other Toyota RAV4 Hybrid owners have reported similar issues, indicating this is a widespread manufacturing defect. Additionally, my wireless charging pad malfunctions and blinks constantly, raising concerns about potential electrical issues in a hybrid vehicle. Given the combination of fuel-related and electrical concerns, I am worried about possible safety risks that could arise from these defects. I am requesting the NHTSA to: 1.Investigate this issue further to determine if it qualifies for an official recall. 2.Require Toyota to take accountability and provide a permanent fix for affected vehicles at no cost to owners. 3.Ensure dealerships honor repairs for vehicles experiencing these known defects. I appreciate your time in reviewing this complaint. Please let me know if any further information is needed to assist in your investigation. Thank you.

Just a little over 33k miles, regular maintenance wit dealer, after the power steering light flashes on then goes off after auto stop of motor when stopping and stop at long intervals sometime see a battery charging at same time. Fluid is great no noise. I see a recall but not on this vin. However I’m reading on line several of these are having the same issue, the car is too new..

I've seen this error message (voltage abnormality steering power low) a few times whenever we are at a stop light and begin to go. This only happens whenever the Start/Stop function is active so the engine is stopped while not moving. Then once we start going, it will show up for a second and then disappear. We have taken the car to a local shop where they said that the alternator was beyond normal use and we received a quote as they believed it was worth replacing. When we went to Toyota dealership as the alternator is still under warranty they said they didn't see anything, they would not allow us to drive the car or hold onto the break in their shop. Problem continues to persist.

There is an issue that seems to be plaguing certain 2021+ Toyota models after a lot of research on this topic. My RAV4 has been operating perfectly and around 42k the Voltage Abnormality: Power Steering Low warning came on. I've had the alternator, starter, and battery tested. Alternator and starter were given a good bill of health, the battery was given a full recharge as it outputting a bit low. The battery was put back into my car and the issue still persists. The issue only occurs after the automatic shut off feature engages when fully stopped at a light or in traffic. If I drive with the feature turned off (something I have to do every time I turn the car on now) the issue doesn't happen. If the issue persists the car can become "locked" and either completely undriveable or a safety hazard to drive if the issue/warning light take full effect and engage the safety features of the car to prevent dangerous driving. Multiple people online are reporting instances of full vehicle seizure on the highway due to this issue and it is becoming a growing safety concern as most cars encountering this issue are reaching 35k+ miles when the issue seems to start occurring on certain vehicles

We’ve had the car for three months had it to the shop of the Toyota place seven times for the electrical issue the car will shut off going down the road when you give a gas when you let off the gas, it will start back up spitting sputter, the instrument cluster The gauges will stick in one spot and not budge and you lose all power to the vehicle to drive

A warning message came up that the HYBRID SYSTEM MALFUNCTION contact dealer. This was confirmed by the dealer. According to the dealer and message boards at various web sites, the Hybrid System Malfunction is NOT uncommon. To fix the problem, a wire harness must be replaced with a replacement cost of $2000-$4000. When I asked what changes have been made to the replacement part to address the corrosion problem, the response was there might be a new coating but we do live in New Hampshire.

I received an error message “Engine stopped, steering power low” after driving an hour in the rain, sat in my car for about 20 mins with wipers on, engine began to jerk aggressively then shut off. I could not gas it or move the car. I let the car sit after being towed, it ran fine as if nothing happened. I got a battery test and it was at 100% charge according to Autozone. The check engine light, battery light and steering light came on. No prior indications of this problem.

The front passenger door started to "not unlock" when using the keys or door buttons to unlock it, you would have to manually unlock the passenger door by reaching across from the driver's side of the car. For about a week, that was happening, then that same door started to "not lock" using the key fob, handle or door buttons, so both locking and unlocking could only be done manually. Then the most concerning incident, while driving and while a passenger was seated in the front seat, upon rounding a corner (moving less than 20 mph) in a very busy town full of parked cars and pedestrians, the closed front passenger door flung open while the vehicle was turning and moving, almost striking a pedestrian and parked car. The passenger was able to safely close the door, but this would have been impossible had there only been a driver in the car at the time. The door had been shut properly, and there were no indicator lights that the door was not fully closed. The door also "auto-locks" when moving, so there were multiple failures of the lock/door system when this occurred. The car was on the road more than 5 minutes when this happened with absolutely no warnings until the door flung open and the car made lots of warning noise at this point. We called the dealer and made an appointment and on the day of the appointment the locks magically started working again. The dealer just charged us $90 to perform a "lock diagnostic" to which they said there are no issues found. Well, let me just say, I feel a door randomly opening in a moving vehicle is a major safety problem and it is a grave concern for me to drive or ride in this car when I am not sure when or if this is going to reoccur at any given moment.

When driving the car and stopping at a stop sign or stop light, the engine will shut off. The automatic restart occurs and with the headlights on the climate temp control display flickers While all the other dashlights remain bright. Many people are disabling the system. Since there is a switch you can press, defeating the system. Toyota sent a technical specialist who inspected the system. And since he couldn't find how to fix it, declared it normal. Apparently toyota designed the car to do this for some unknown reason. He stated That lights will dim when the car restarts. It is not dimming as if a current draw, it flickers every time. This of course, affects the fuel economy of the car, defeating the system, which many people do and creates a concern of why that one component flickers. Toyota installs a heavy 605A battery to operate this system Since there are so many restarts. Will this create a car fire at some point? I would imagine That it makes a difference in The cafe reporting since so many people Disable the system.