Electronic Stability Control (esc)EngineUnknown Or Other
VEHICLE WAS IN MOTION ON RAINY, WET HIGHWAY WHEN CHECK ENGINE LIGHT WENT ON AND TRACTION CONTROL WAS SHUT OFF. THE SECONDARY AIR INJECTION SWITCHING VALVE IS APPARENTLY STUCK CLOSED, WHICH FOR SOME REASON SHUTS OFF THE TRACTION CONTROL. IT IS MY UNDERSTANDING FROM SPEAKING WITH OTHER TACOMA AND TUNDRA OWNERS THAT HAD THE VALVES …
Read full complaint
VEHICLE WAS IN MOTION ON RAINY, WET HIGHWAY WHEN CHECK ENGINE LIGHT WENT ON AND TRACTION CONTROL WAS SHUT OFF. THE SECONDARY AIR INJECTION SWITCHING VALVE IS APPARENTLY STUCK CLOSED, WHICH FOR SOME REASON SHUTS OFF THE TRACTION CONTROL. IT IS MY UNDERSTANDING FROM SPEAKING WITH OTHER TACOMA AND TUNDRA OWNERS THAT HAD THE VALVES GOTTEN STUCK OPEN, THE VEHICLE GOES INTO "LIMP MODE" WHICH AUTOMATICALLY DECREASES SPEED TO 20MPH. OBVIOUSLY, EITHER OF THESE OCCURRENCES ARE PARTICULARLY UNSAFE IN RAINY AND WET CONDITIONS, AND THE DECREASE IN SPEED IS UNSAFE DURING ANY HIGHWAY TRAVELING. THIS IS APPARENTLY A BIG ENOUGH ISSUE ON THE TUNDRA MODELS FOR TOYOTA TO EXTEND THE WARRANTY TO 150,000MI, YET THEY HAVE DONE NOTHING FOR THE TACOMAS WHICH HAVE AN IDENTICAL SYSTEM AND PARTS.
NHTSA ODI #10992726
58,500 miles · May 21, 2017
Unknown Or Other
SECONDARY AIR INJECTION PUMP. RECEIVING P2442 CODE AND TRUCK IS GOING IN TO LIMP MODE
NHTSA ODI #10990807
69,500 miles · Apr 11, 2017
Unknown Or Other
ERROR 2440/2442 CAME UP A FEW DAYS AGO WHEN STARTING THE TRUCK TO GO TO WORK(COOL MORNING) - SECONDARY AIR INJECTION SYSTEM SWITCHING VALVE STUCK OPEN BANK 1/2. I FIRST NOTICED THAT IT INDEED PUT THE TRUCK INTO LIMP MODE, WHICH CAUSES THE ENGINE TO DECREASE POWER SO I COULD HARDLY ACCELERATE.(PRESSURE SENSOR IN EXHAUST WENT OFF …
Read full complaint
ERROR 2440/2442 CAME UP A FEW DAYS AGO WHEN STARTING THE TRUCK TO GO TO WORK(COOL MORNING) - SECONDARY AIR INJECTION SYSTEM SWITCHING VALVE STUCK OPEN BANK 1/2. I FIRST NOTICED THAT IT INDEED PUT THE TRUCK INTO LIMP MODE, WHICH CAUSES THE ENGINE TO DECREASE POWER SO I COULD HARDLY ACCELERATE.(PRESSURE SENSOR IN EXHAUST WENT OFF BECAUSE VALVES WERE STUCK OPEN) I KNEW EXACTLY WHAT THE PROBLEM WAS DUE TO MANY HAVING THE SAME ISSUES ON A TACOMA FORUM I AM ON.(ALL WITH EARLY 2012'S, A REDESIGNED PUMP WAS MADE AND INSTALLED ON LATER BUILT 2012S) I TOOK APART THE SYSTEM AFTER GETTING A SHAFT FROM MY LOCAL DEALER SAYING IT WAS UNDER POWERTRAIN WARRANTY.(KNEW IT WAS UNLIKELY AS I HAVE ALMOST 70K MILES, BUT THOUGHT WHY NOT TRY) AFTER READING ABOUT OTHER'S WAYS OF SOLVING THE ISSUE, I TOOK APART BOTH THE AIR PUMP AND VALVE ASSEMBLY TO INSPECT THEM. I WAS AMAZED TO FIND A SOAKED AIR FILTER WITH WATER SITTING IN THE PLASTIC MOLDING UNDER IT, I ALSO FOUND THE RUBBER HAD BEEN BURNT UP IN THE VALVE ASSEMBLY, ALONG WITH DEPOSITS DUE TO MOISTURE.(PICTURES ATTACHED) FROM WHAT I HAVE READ, AND WHAT I HAVE SEEN, TOYOTA INSTALLED THIS DEFECTIVE SYSTEM ON EARLY 2012 TACOMA'S BEFORE A REDESIGNED PUMP(NOT SURE ON VALVES) AND PROGRAMMING THAT IS SUPPOSED TO RUN THE AIR PUMP AFTER THE ENGINE SHUTS OFF TO GET RID OF THE MOISTURE. I BOUGHT NEW VALVES FOR $479, BUT WILL ALSO HAVE TO BUY A BYPASS FOR $350 BECAUSE I KNOW THE AIR PUMP WILL STILL BRING IN MOISTURE AND CAUSE THE VALVES TO FAIL AGAIN, THIS BYPASS ALLOWS THE PUMP/VALVES TO COMMUNIATE TO ECU THAT THEY RUN OK BUT THE AIR PUMP NEVER RUNS. TOYOTA ISSUED A TSB FOR TUNDRA'S AND SEQUIOA'S FOR THE SAME REASON, YET THEY ARE IGNORING TACOMAS.(ATTACHED PDF) ALSO JUST NOTICED ON THIS TSB THEY WERE VERY QUICK ABOUT ISSUING IT AS WELL, CAN'T SEE HOW THEY DIDN'T KNOW THAT TACOMA'S HAD THE SAME SYSTEM INSTALLED.
NHTSA ODI #10971900
50,000 miles · Apr 3, 2017
Unknown Or Other
P2440-P2442 ERROR CODE. SECONDARY AIR INJECTION VALVES AND PUMP. A POORLY ENGINEERED PART THAT CONTINUES TO BREAK AND TOYOTA WONT ADDRESS THE ISSUE LIKE IT HAS ON THE TUNDRA & SEQUANA (SP). THEY KNOW THEY HAVE A BAD PART .
NHTSA ODI #10970146
50,706 miles · Mar 24, 2017
Unknown Or Other
I WAS DRIVING TO WORK THIS MORNING AND WHEN ENTERING A HIGHWAY MY TRUCK COMPLETELY STOPPED ACCELERATING AND WOULD NOT GO OVER 40 MPH, ANF WOULD NOT GO OVER 1200 RPMS. I HAVE RESEARCHED THE CODES THAT POPPED UP FROM MY CHECK ENGINE LIGHT, AND HAVE FOUND A TON OF OTHER PEOPLE ARE HAVING THE SAME ISSUE. THE CODE IS P2442, AND INDIC…
Read full complaint
I WAS DRIVING TO WORK THIS MORNING AND WHEN ENTERING A HIGHWAY MY TRUCK COMPLETELY STOPPED ACCELERATING AND WOULD NOT GO OVER 40 MPH, ANF WOULD NOT GO OVER 1200 RPMS. I HAVE RESEARCHED THE CODES THAT POPPED UP FROM MY CHECK ENGINE LIGHT, AND HAVE FOUND A TON OF OTHER PEOPLE ARE HAVING THE SAME ISSUE. THE CODE IS P2442, AND INDICATES A FAILED AIR INJECTOR THAT THE MANUFACTURER HAS NOT ISSUED A RECALL OR SAFETY ADVISORY.
NHTSA ODI #10968390
63,000 miles · Mar 14, 2017
Unknown Or Other
CHECK ENGINE LIGHT AND TRAC OFF APPEARED AND TRUCK ENTERED LIMP MODE. CODES P2440/P2442 ON DIAGNOSTICS. SECONDARY AIR INVERTER FAILED ALONG WITH AIR PUMP. EMISSIONS CONTROL PROBLEMS. TOYOTA DID NOT ACKNOWLEDGE ANY RESPONSIBILITY.
NHTSA ODI #10965987
65,000 miles · Mar 13, 2017
Unknown Or Other
A PROBLEM COMMON TO TOYOTA'S OCCURRED WITH MY VEHICLE. THE SECONDARY AIR INJECTION PUMP FAILED. THE TACOMA DID NOT HAVE SUFFICIENT POWER AND WOULD NOT REACH CERTAIN RPM'S. THE BILL IS $2,500. THE DEALERSHIP TOLD ME IT HAPPENS QUITE OFTEN WITH TOYOTAS. THEY HAVE SAID THIS IS NOT PART OF THE POWERTRAIN WARRANTY.
NHTSA ODI #10960321
57,000 miles · Feb 25, 2017
Unknown Or Other
AT 57000 MILES CHECK ENGINE AND GETTING P2442 CODE AT START-UP. CHECKED AND IT IS A BAD SECONDARY INJECTION PUMP. CHECKED ON INTERNET AND THERE ARE MANY OTHERS WITH THE SAME PROBLEM AND TOYOTA SAYS IT'S NOT UNDER WARRANTY $1900 TO FIX
NHTSA ODI #10956951
40,000 miles · Feb 20, 2017
Unknown Or Other
THE ENGINE LIGHT CAME ON - TOOK TO DEALER - WAS TOLD SECONDARY AIR FLOW AND PUMP NEED TO BE REPLACED.
NHTSA ODI #10955562
40,964 miles · Dec 29, 2016
EngineUnknown Or Other
HEADED TO WORK TO FIND CHECK ENGINE LIGHT ILLUMINATED. TRUCK HAS LESS THAN 41,000 MILES. WENT TO AUTOZONE, CODE READER PROVIDED P2442 AND P2440 ERRORS RELATED TO THE SECONDARY AIR INJECTION SYSTEM VALVES. FOLLOWED UP WITH LOCAL TOYOTA DEALER. DEALER RAN DIAGNOSTIC AND FOUND SECONDARY AIR INJECTION SYSTEM VALVES STUCK OPEN IN BAN…
Read full complaint
HEADED TO WORK TO FIND CHECK ENGINE LIGHT ILLUMINATED. TRUCK HAS LESS THAN 41,000 MILES. WENT TO AUTOZONE, CODE READER PROVIDED P2442 AND P2440 ERRORS RELATED TO THE SECONDARY AIR INJECTION SYSTEM VALVES. FOLLOWED UP WITH LOCAL TOYOTA DEALER. DEALER RAN DIAGNOSTIC AND FOUND SECONDARY AIR INJECTION SYSTEM VALVES STUCK OPEN IN BANKS 1 AND 2. DEALER WANTS TO REPLACE PARTS 17600-0P040: PUMP ASSEMBLY; 25710-31022: VALVE ASSEMBLY; AND THE 4 RELATED GASKETS, PART 17377-31010. QUOTE WAS FOR ALMOST $2400. AGAIN, THE VEHICLE IS 2012, LESS THAN 41K MILES! RESEARCHING THE TACOMA FORUMS ONLINE, THIS APPEARS TO BE A COMMON PROBLEM WITH THIS GENERATION MODEL AND MORE EVEN MORE SO WITH 2012'S. ONE OF THE DEALER'S SERVICE ADVISORS INFORMED ME THAT THIS IS ALSO A COMMON PROBLEM WITH TUNDRAS. FURTHERMORE, WHILE DRIVING, THE VEHICLE WOULD GO IN AND OUT OF "LIMP MODE" AND I HAD NO WARNING AS TO WHEN IT WOULD OR WOULD NOT BE IN THIS MODE, OTHER THAN BY THE WAY THE VEHICLE WAS HANDLING. LIMP MODE WOULD ONLY ALLOW TRANSMISSION TO SHIFT INTO 2ND OR 3RD AND NO MORE THAN 30 MPH, LESS IF CLIMBING AN INCLINE. AT OTHER TIMES, VEHICLE WOULD DRIVE NORMALLY. THE SWITCHING IN AND OUT OF THIS PROTECTIVE MODE SEEMS PARTICULARLY DANGEROUS. *TR
Southeast Toyota Distributors, LLC (SET) is recalling certain 2011-2016 Toyota Tacoma and 4Runner vehicles equipped with accessory hood scoops installed by SET or SET dealers. The adhesive attaching the hood scoop may weaken, allowing the hood scoop to detach from the vehicle.
Consequence & remedy
Consequence: If the hood scoop detaches, it may become a road hazard, increasing the risk of a crash.
Remedy: SET will notify owners, and dealers will mechanically fasten the scoop to the hood, free of charge. The recall began on September 1, 2017. Owners may contact SET customer service at 1-954-429-2000. SET's number for this recall is SET17B.
Additional source detail variants (2)
Equipment
Southeast Toyota Distributors, LLC (SET) is recalling certain 2011-2016 Toyota Tacoma and 4Runner vehicles equipped with accessory hood scoops installed by SET or SET dealers. The adhesive attaching the hood scoop may weaken, allowing the hood scoop to detach from the vehicle.
Consequence: If the hood scoop detaches, it may become a road hazard, increasing the risk of a crash.
Remedy: SET will notify owners, and dealers will mechanically fasten the scoop to the hood, free of charge. The recall began on September 1, 2017. Owners may contact SET customer service at 1-954-429-2000. SET's number for this recall is SET17B.
Structure:body:hood:hinge And Attachments
Southeast Toyota Distributors, LLC (SET) is recalling certain 2011-2016 Toyota Tacoma and 4Runner vehicles equipped with accessory hood scoops installed by SET or SET dealers. The adhesive attaching the hood scoop may weaken, allowing the hood scoop to detach from the vehicle.
Consequence: If the hood scoop detaches, it may become a road hazard, increasing the risk of a crash.
Remedy: SET will notify owners, and dealers will mechanically fasten the scoop to the hood, free of charge. The recall began on September 1, 2017. Owners may contact SET customer service at 1-954-429-2000. SET's number for this recall is SET17B.
Toyota Motor Engineering & Manufacturing (Toyota) is recalling certain model year 2008-2014 FJ Cruiser and Tacoma vehicles equipped with accessory wheels and tires installed by Toyota or dealers prior to the vehicle's first sale. The affected vehicles may list incorrect spare tire size and/or cold tire inflation information on the tire placard. As such, these vehicles fail to comply with Federal Motor Vehicle Safety Standard No. 110, "Tire Selection and Rims for Passenger Cars."
Consequence & remedy
Consequence: If the spare tire is inflated to the incorrect pressure provided on the placard, tire failure may occur while it is being driven on, increasing the risk of a crash.
Remedy: For the involved vehicles, overlay stickers to correct the tire placard will either be mailed to owners or provided to dealers for placement over the incorrect information on the placard. The recall is expected to begin in September 2014. Owners may contact Toyota customer service at 1-800-331-4331.
Toyota is recalling certain model year 2012 and 2013 Toyota Tacoma and Lexus RX350 vehicles and certain model year 2012 Toyota Rav4 vehicles. In the affected vehicles, the brake system contains a brake actuator that adjusts the fluid pressure of each wheel cylinder. An electrical component within the actuator may experience an increased resistance resulting in the illumination of various warning lights, including those for the Vehicle Stability Control (VSC) system, Antilock Brake System (ABS), and Traction Control system.
Consequence & remedy
Consequence: If this occurs, these systems could become inoperative, reducing the directional control assistance, increasing the risk of a crash.
Remedy: Toyota will notify owners, and Toyota and Lexus dealers will update the software for the Skid Control electronic control unit, free of charge. The recall began on March 28, 2014. Owners may contact Toyota at 1-800-331-4331.
Additional source detail variants (2)
Electronic Stability Control (esc)
Toyota is recalling certain model year 2012 and 2013 Toyota Tacoma and Lexus RX350 vehicles and certain model year 2012 Toyota Rav4 vehicles. In the affected vehicles, the brake system contains a brake actuator that adjusts the fluid pressure of each wheel cylinder. An electrical component within the actuator may experience an increased resistance resulting in the illumination of various warning lights, including those for the Vehicle Stability Control (VSC) system, Antilock Brake System (ABS), and Traction Control system.
Consequence: If this occurs, these systems could become inoperative, reducing the directional control assistance, increasing the risk of a crash.
Remedy: Toyota will notify owners, and Toyota and Lexus dealers will update the software for the Skid Control electronic control unit, free of charge. The recall began on March 28, 2014. Owners may contact Toyota at 1-800-331-4331.
Service Brakes, Hydraulic:antilock/traction Control/electronic Limited Slip:control Unit/module
Toyota is recalling certain model year 2012 and 2013 Toyota Tacoma and Lexus RX350 vehicles and certain model year 2012 Toyota Rav4 vehicles. In the affected vehicles, the brake system contains a brake actuator that adjusts the fluid pressure of each wheel cylinder. An electrical component within the actuator may experience an increased resistance resulting in the illumination of various warning lights, including those for the Vehicle Stability Control (VSC) system, Antilock Brake System (ABS), and Traction Control system.
Consequence: If this occurs, these systems could become inoperative, reducing the directional control assistance, increasing the risk of a crash.
Remedy: Toyota will notify owners, and Toyota and Lexus dealers will update the software for the Skid Control electronic control unit, free of charge. The recall began on March 28, 2014. Owners may contact Toyota at 1-800-331-4331.
Southeast Toyota Distributors, LLC (SET) is recalling certain model year 2012-2013 Tacoma vehicles equipped with 18" Maverick Alloy Wheels. In the affected vehicles, the spare tire requires the use of a different style of lug nut to attach it to the vehicle than the other wheels use. These lug nuts were not provided with the vehicle.
Consequence & remedy
Consequence: If the spare tire/wheel is installed on the vehicle using the lug nuts from another wheel, damage to the wheel could result and may eventually lead to a loose wheel, increasing the risk of a crash.
Remedy: SET will notify owners, and dealers will: (a) Install a Warning Label on the spare tire/wheel, (b) supply a bag containing proper spare wheel lug nuts, and (c) place an Owner's Manual Addendum in the vehicle's glove box. The recall began on January 23, 2014. Owners may contact SET at 1-954-429-2000.
Southeast Toyota is recalling certain model year 2008 and 2010-2013 Toyota Tundra, 2010-2012 Rav4, 2012 Toyota Sequoia, 2010-2011 Toyota Corolla, 2010-2011 Toyota Camry and Camry Hybrid, 2010-2013 Toyota Highlander and Highlander Hybrid, 2010-2013 Toyota FJ Cruiser, 2011 Toyota Land Cruiser, 2010-2013 Toyota Venza, 2010-2011 Toyota 4Runner, 2010-2013 Toyota Tacoma, 2011-2012 Toyota Sienna, 2012 Toyota Prius, 2013 Scion FR-S, 2011 Scion XD, 2011 Scion XB, and 2012 Scion TC vehicles. These vehicles were sold with labels that were outside the allowable one percent of accuracy of actual weight added. Thus, 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 inaccurate label could lead to owners overloading their vehicles and tires. An overloaded vehicle can result in a tire failure which may result in a vehicle crash, personal injury, or property damage.
Remedy: Southeast Toyota will notify owners and provide a corrected label with instructions concerning its installation. A small group of the affected vehicles will need additonal remedies which are still being developed. The recall began on May 28, 2013. Owners may contact Southeast Toyota at 1-800-301-6859.
Southeast Toyota Distributors, LLC (SET) is recalling certain models interspersed through model years 2009 through 2013 as follows: model year 2009-2012 Tacoma, 4Runner, Camry, Camry Hybrid, Prius, and RAV4; model year 2009-2010 Avalon, FJ Cruiser, and Highlander Hybrid; model year 2010-2013 model year Corolla, Sienna and Tundra; model year 2009-2013 Highlander and Venza; model year 2012 Prius V; and model year 2010-2012 Sequoia. During modification by SET to include accessories such as leather seat covers, seat heaters or headrest DVD systems, these vehicles may not have had the passenger seat occupant sensing system calibration tested. Without passing the calibration test, the occupant sensing system may not operate as designed.
Consequence & remedy
Consequence: If the front passenger seat occupant sensing system is out of calibration, the front passenger airbags may not deploy or they may deploy inappropriately for the passenger's size and position. This could increase the risk of personal injury during the event of a vehicle crash necessitating airbag deployment.
Remedy: Southeast Toyota will notify owners, and dealers will test the sensitivity of the occupant detection sensors, and recalibrate them as necessary. The recall began on March 21, 2013. Owners may contact Southeast Toyota at 1-800-301-6859.
Additional source detail variants (2)
Seats
Southeast Toyota Distributors, LLC (SET) is recalling certain models interspersed through model years 2009 through 2013 as follows: model year 2009-2012 Tacoma, 4Runner, Camry, Camry Hybrid, Prius, and RAV4; model year 2009-2010 Avalon, FJ Cruiser, and Highlander Hybrid; model year 2010-2013 model year Corolla, Sienna and Tundra; model year 2009-2013 Highlander and Venza; model year 2012 Prius V; and model year 2010-2012 Sequoia. During modification by SET to include accessories such as leather seat covers, seat heaters or headrest DVD systems, these vehicles may not have had the passenger seat occupant sensing system calibration tested. Without passing the calibration test, the occupant sensing system may not operate as designed.
Consequence: If the front passenger seat occupant sensing system is out of calibration, the front passenger airbags may not deploy or they may deploy inappropriately for the passenger's size and position. This could increase the risk of personal injury during the event of a vehicle crash necessitating airbag deployment.
Remedy: Southeast Toyota will notify owners, and dealers will test the sensitivity of the occupant detection sensors, and recalibrate them as necessary. The recall began on March 21, 2013. Owners may contact Southeast Toyota at 1-800-301-6859.
Air Bags:frontal:sensor/control MODULE-INACTIVE
Southeast Toyota Distributors, LLC (SET) is recalling certain models interspersed through model years 2009 through 2013 as follows: model year 2009-2012 Tacoma, 4Runner, Camry, Camry Hybrid, Prius, and RAV4; model year 2009-2010 Avalon, FJ Cruiser, and Highlander Hybrid; model year 2010-2013 model year Corolla, Sienna and Tundra; model year 2009-2013 Highlander and Venza; model year 2012 Prius V; and model year 2010-2012 Sequoia. During modification by SET to include accessories such as leather seat covers, seat heaters or headrest DVD systems, these vehicles may not have had the passenger seat occupant sensing system calibration tested. Without passing the calibration test, the occupant sensing system may not operate as designed.
Consequence: If the front passenger seat occupant sensing system is out of calibration, the front passenger airbags may not deploy or they may deploy inappropriately for the passenger's size and position. This could increase the risk of personal injury during the event of a vehicle crash necessitating airbag deployment.
Remedy: Southeast Toyota will notify owners, and dealers will test the sensitivity of the occupant detection sensors, and recalibrate them as necessary. The recall began on March 21, 2013. Owners may contact Southeast Toyota at 1-800-301-6859.
GULF STATES TOYOTA (GST) IS RECALLING CERTAIN MODEL YEAR 2012 TACOMA TRUCKS. THE TIRE AND LOADING INFORMATION PLACARD ON EACH VEHICLE CONTAINS INACCURATE SPARE TIRE SIZE AND COLD INFLATION PRESSURE INFORMATION. THUS, THESE VEHICLES FAIL TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 110,TIRE SELECTION AND RIMS.
Consequence & remedy
Consequence: AN INCORRECT PLACARD COULD LEAD TO IMPROPER SPARE TIRE USE OR REPLACEMENT WHICH COULD RESULT IN A TIRE FAILURE, INCREASING THE RISK OF A CRASH.
Remedy: GST WILL NOTIFY OWNERS, AND SEND EACH OWNER A CORRECTED PLACARD, FREE OF CHARGE. THE SAFETY RECALL BEGAN ON JUNE 5, 2012. OWNERS MAY CONTACT GULF STATES TOYOTA, INC. AT 1-713-744-3465.
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
EA19001 · Electrical Overstress
Opened Apr 19, 2019 · Closed Sep 19, 2024
Status: closed (inferred from source dates) · Air Bags: Air Bag/restraint Control Module
The Office of Defects Investigation (ODI) opened this investigation to determine if the failure of airbags to deploy during severe crashes, in certain vehicles, was the result of a safety related defect. During the investigation a complex failure was studied that can result in non-deployment of subject vehicle air bags and other restraint system devices in severe crash events. The subject vehicles may be equipped with an airbag control unit (ACU) for the supplemental restraint system (SRS) Electronic Control Unit (ECU) manufactured by ZF-TRW. The ECU receives signals from crash sensors mounted in the vehicle and deploys the vehicle air bags and seat belt pretensioners in accordance with manufacturer design specifications. The ECU in the subject vehicles contains a model DS84 application-specific integrated circuit (ASIC) which controls the communication of the crash sensor signal, firing commands (i.e., when to deploy the airbag(s) and/or pretensioners), and fault information (e.g., diagnostic trouble codes). In September 2016, FCA announced recall 16V-668 for certain model year (MY) 2010 to 2014 Chrysler, Dodge and Jeep products manufactured with the subject ZF-TRW ACU. In this recall, FCA discussed an EOS condition that resulted in a failure of the subject DS84 ASIC, which caused air bag non-deployment. FCA noted that the defect condition had only been observed in vehicles equipped with sensor harnessing routed across the front of the vehicle. Other FCA vehicles that also used the subject ACU, but were not equipped with cross-car harnessing, had not experienced EOS failures, despite similar time in service. During the course of this investigation, ODI sent two separate Information Request (IR) letters to six vehicle manufactures (including FCA, Hyundai, Honda, Kia, Mitsubishi, and Toyota) and one IR letter to ZF-TRW. These IR letters resulted in ODI receiving comprehensive data from these manufacturers and suppliers. Studies of this data found that the DS84 ASIC does not have sufficient protection against negative electrical transients or electrical overstress (“EOS”) that can be generated in certain severe crashes. An electrical transient occurs when the electrical power supplied to a circuit changes momentarily over a short duration of time. In these severe crash cases, the crash sensors and other powered wiring can be damaged and short circuited so as to create a negative electrical transient of sufficient intensity and duration (that are outside the vehicle manufacturer's specification) to damage the ASIC before the restraint device deployment signal is received by the SRS ECU. This damaged signal can lead to incomplete or nondeployment of the air bags and/or pretensioners. Airbag non-deployment and/or lack of pretensioner operation can increase the risk or severity of injury in a crash.A total of 8 fatalities and 14 injuries were associated with known EOS events. The common element in all investigated manufacturers vehicles is the SRS ECU containing a DS84 ASIC manufactured by ZF-TRW. The risk associated with the ASIC is equally shared among all OEMS involved in the investigation. The actual real-world risk can be mitigated by other factors which were assessed by ODI during this investigation. The first mitigating factor involves protections built into the ACU design which protect the DS84 ASIC from damage. There are multiple strategies and levels of protection employed by different OEMs that provide effective EOS mitigation. The two most common strategies at the ACU level are circuit protection diodes on the remote senor signal lines, and current limiting resistors that protect critical components. The second mitigating factor is found at the vehicle level and involves the location and routing of the wires leading from the crash sensors to the SRS ECU. If the wires are well protected in a crash and are not routed with other power wires carrying large currents, the risk for an EOS event is significantly reduced or eliminated. These design specific factors combine to produce a spectrum of risk for the vehicles equipped with ACUs using the DS84 ASIC. Given the many of years of field exposure, it is possible to divide the subject population into two groups; vehicles which have experienced EOS events, and vehicles which have not experienced EOS field events. Four of the six OEMs involved in this investigation have experienced EOS field events on at least one of their models equipped with a DS84 ASIC. All vehicle models (including the Toyota models identified in the Failure Report Summary of the opening resume for this investigation) with field events have been recalled. In an abundance of caution, ODI kept this investigation open five years to monitor field performance and did not identify any field events on vehicles not included in existing safety recalls. Given the spectrum of risk identified in this investigation and that all vehicles with a demonstrated unreasonable risk have been recalled, ODI is closing this investigation. ODI is closing this investigation with the following manufacturer safety recalls: 16V-668, 18E-043, 18V-137, 18V-363, and 20V-024. With the recall actions taken by the subject vehicle and equipment manufacturers, this investigation is closed. The closing of this investigation does not constitute a finding by NHTSA that a safety-related defect does not exists on other model or model year vehicles outside of the recall scopes. The agency reserves the right to take further action if warranted by the circumstances.
2012 Toyota Tacoma Problems, Complaints & Recalls | Skip That Year