2024 TOYOTA BZ4X

VISIBILITY:DEFROSTER/DEFOGGER/HVAC SYSTEM

Toyota Motor Engineering & Manufacturing (Toyota) is recalling certain 2023-2025 bZ4X, Lexus RZ, and Subaru Solterra vehicles. During certain HVAC system faults, such as electrical compressor failure, the defroster and defogger system may become inoperative.

Risk: An inoperative defroster and defogger system can decrease the driver's visibility under certain driving conditions, increasing the risk of a crash.

ELECTRICAL SYSTEM

The 12 volt battery does not maintain a charge. I have had it replaced twice. I purchased new January 2025; first battery replaced on March 20, 2025; second battery replaced August 13, 2025. I am currently having the same issue with the battery management system which controls temperature and battery usage. After sitting overnight, I drove my car approximately three miles parked and attempted to use the key fob to secure the vehicle, it failed. I had no problem or indication at the start of my trip. I had to secure the door with my physical key. I returned to the vehicle 15 minutes later and the key fob would not work at all. I accessed the vehicle with the physical key. The alarm was activated upon entry. I tried to use my key fob to get the vehicle to deactivate the alarm system but it would not work. Approximately five minutes later and after several attempts, the alarm stopped and the vehicle was showing ‘Ready’ but ‘No Key Detected’ was flashing on the information screen and vehicle would not change mode from park to reverse or drive. After several attempts of holding the key fob directly over the ‘START/STOP’ button, the car showed ‘ READY’ and I was able to change modes. The vehicle started flashing ‘NO KEY DETECTED’ continuously while I quickly drove back home. I parked in my driveway and made an appointment with Toyota for service. Later in the day, I attempted my key fob again, to no avail. I was able to get the key detected, display showed ‘Ready’ and mode changed. My car does not start (READY) until after several attempts. The dealership advised the battery failed a load test overnight and was replaced (August 15th) After the second replacement my car sat overnight. I drove a few miles to a charging station. I placed the car in ‘My Room Mode’ to have access to the climate control system and radio. The car started flashing ‘low voltage/battery’, I turned off the accessory mode, returned to the dealer, and awaiting resolution. Case filed with NCDS/CDSP.

VISIBILITY:REARVIEW MIRRORS/DEVICES:EXTERIOR

I am very concerned about potential accidents for my self and others driving this vehicle. I have multiple close call accidents because the left view mirror does't have proper view to see cars on left side especially if they are close. The way seat and the side of the vehicle is shaped its very hard to still see manually with head turned to the left rear side. The mirror or the shape or position needs to be changed for safety to prevent accidents.

SEATS

I am very concerned about potential accidents for my self and others driving this vehicle. I have multiple close call accidents because the left view mirror does't have proper view to see cars on left side especially if they are close. The way seat and the side of the vehicle is shaped its very hard to still see manually with head turned to the left rear side. The mirror or the shape or position needs to be changed for safety to prevent accidents.

LANE DEPARTURE: BLIND SPOT DETECTION

I am very concerned about potential accidents for my self and others driving this vehicle. I have multiple close call accidents because the left view mirror does't have proper view to see cars on left side especially if they are close. The way seat and the side of the vehicle is shaped its very hard to still see manually with head turned to the left rear side. The mirror or the shape or position needs to be changed for safety to prevent accidents.

STRUCTURE:BODY

LEFT FRONT FENDER AND HOOD CONTACTED UPON GOING INTO A DIP IN THE ROAD DURNING ROAD CONTRUCTION PERFORMED BY BITUMINOUS ROADWAYS, INC. DAMAGE TO FENDER AND HOOD. VEHICLE BODY AND OR FRAME WISTED. BROUGHT THE VEHICLE TO LAMETTRY'S IN BURNSVILLE MINNESOTA. THEY STAED THAT THE DIP IN THE ROAD MAY HAVE CAUSED THIS CONDITION AS SEEN FROM THE SCRAPE MARKS ON LATCH. TOYOTA DEALER INSPRSTION AND CASE OPENED. CRUNCH NOISE HEARD DURING INCIDENT.

AIR BAGS

Driver sustained severe hand injuries due to airbag deployment while the hand was on the horn pad. Possible over-aggressive deployment or module failure. Incident occurred on [XXX], while driving a 2024 Toyota BZ4X (VIN: [XXX] ). Requesting formal investigation into the airbag system and front structural integrity of this vehicle model. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

STRUCTURE:BODY:BUMPERS

On [XXX], while driving through a common roadway puddle at a safe speed, the front bumper on my BZ4X detached from the undercarriage shield and tore away from the clips. This type of damage is clearly disproportionate to the conditions and reflects a deficiency in structural design. After researching this issue, I found that many other BZ4X owners have experienced the same bumper detachment and undercarriage shield failure under minimal driving conditions. These consistent reports indicate a widespread manufacturing defect, not isolated driver error or negligence. For example: On multiple owner forums and complaint sites like NHTSA.gov and Reddit, BZ4X owners have documented similar instances of bumpers tearing off from puddles or light snow. A widely circulated post on Reddit’s r/Toyota described a nearly identical issue, stating that “driving through a shallow puddle at a slow speed caused the bumper to rip off like paper.” The issue has even reached automotive press outlets and consumer advocate blogs, highlighting growing concern over the poor mounting of the bumper and the fragile undercarriage shield. Given the consistency and severity of these reports, this clearly represents a design flaw. The bumper is failing to withstand routine driving conditions, and this undermines not only the durability of the vehicle but also customer confidence and safety. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

STRUCTURE:FRAME AND MEMBERS:UNDERBODY SHIELDS

On [XXX], while driving through a common roadway puddle at a safe speed, the front bumper on my BZ4X detached from the undercarriage shield and tore away from the clips. This type of damage is clearly disproportionate to the conditions and reflects a deficiency in structural design. After researching this issue, I found that many other BZ4X owners have experienced the same bumper detachment and undercarriage shield failure under minimal driving conditions. These consistent reports indicate a widespread manufacturing defect, not isolated driver error or negligence. For example: On multiple owner forums and complaint sites like NHTSA.gov and Reddit, BZ4X owners have documented similar instances of bumpers tearing off from puddles or light snow. A widely circulated post on Reddit’s r/Toyota described a nearly identical issue, stating that “driving through a shallow puddle at a slow speed caused the bumper to rip off like paper.” The issue has even reached automotive press outlets and consumer advocate blogs, highlighting growing concern over the poor mounting of the bumper and the fragile undercarriage shield. Given the consistency and severity of these reports, this clearly represents a design flaw. The bumper is failing to withstand routine driving conditions, and this undermines not only the durability of the vehicle but also customer confidence and safety. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

STRUCTURE:BODY

I was driving very slowly (5 to 10 MPH) through a rain storm on May 28th. The water rose to about 6 inches (fairly still, not rushing water), and I heard a loud and alarming noise under the car. I drove on for one block on a neighborhood street until I could get to higher ground. I discovered that the force of the water pulled down the fabric and plastic shrouds from the wheel-well into the wheels. The cloth and plastic shrouds were then pulled under the wheels, and the whole connected assembly was ripped off the car. This caused damage to both front fenders, the front bumper, and possibly to the safety sensors behind the bumper. I took it to my local Toyota dealer the next day, and they said this happens all the time, and that it will cost at least $2,000 to repair -- maybe double that if the safety sensors behind the bumper were damaged. I posted to some forums on-line about this problem, and heard from many other owners of the BZ4X and the identical car from Subaru (Soltera) that they had experienced the same thing. The Toyota dealer is correct -- this happens all the time -- it is clearly a serious design flaw, and it is a serious safety concern. The Toyota dealer has said that this is my problem, not theirs. The Toyota USA customer-service said the same thing. They clearly do not want to accept responsibility for a badly designed front-bumper assembly. This car has less than 3,000 miles on it, and despite my extremely cautious driving, it is already falling apart.

LANE DEPARTURE: ASSIST

Steering system, potentially related to electric power steering (EPS) or driver-assist systems (lane keeping or steering assist). While completing a routine right-hand turn, my husband began to straighten the steering wheel when the steering system suddenly and sharply turned further right without any driver input. This caused the vehicle to strike a curb, damaging both passenger-side wheels and the front tire. There were no warning lights or indicators, and road and weather conditions were normal. The uncommanded steering input appeared to come from the vehicle itself. The incident resulted in loss of directional control and could have been severe had another vehicle, pedestrian, or cyclist been present. This behavior reflects a serious and unexpected failure in the steering or driver-assist system, posing a direct threat to driver and public safety. I reported the incident to my local Toyota dealership. I have since signed Toyota’s EDR (Event Data Recorder) consent form, and an official inspection has occurred but they haven't provided detail. They also did not make me aware the inspection was taking place and did it without coordination. They have not confirmed that this has happened before. A similar, though less severe, issue occurred previously while I was driving on the highway. As I approached a merging lane to my right, the car suddenly pulled sharply to the right, seemingly misinterpreting the lane markings or misjudging its position. There were no vehicles next to me at the time, and I was able to regain control. While it did not result in a collision, it was alarming and appears to have been a driver-assist or steering control malfunction.

WHEELS

Steering system, potentially related to electric power steering (EPS) or driver-assist systems (lane keeping or steering assist). While completing a routine right-hand turn, my husband began to straighten the steering wheel when the steering system suddenly and sharply turned further right without any driver input. This caused the vehicle to strike a curb, damaging both passenger-side wheels and the front tire. There were no warning lights or indicators, and road and weather conditions were normal. The uncommanded steering input appeared to come from the vehicle itself. The incident resulted in loss of directional control and could have been severe had another vehicle, pedestrian, or cyclist been present. This behavior reflects a serious and unexpected failure in the steering or driver-assist system, posing a direct threat to driver and public safety. I reported the incident to my local Toyota dealership. I have since signed Toyota’s EDR (Event Data Recorder) consent form, and an official inspection has occurred but they haven't provided detail. They also did not make me aware the inspection was taking place and did it without coordination. They have not confirmed that this has happened before. A similar, though less severe, issue occurred previously while I was driving on the highway. As I approached a merging lane to my right, the car suddenly pulled sharply to the right, seemingly misinterpreting the lane markings or misjudging its position. There were no vehicles next to me at the time, and I was able to regain control. While it did not result in a collision, it was alarming and appears to have been a driver-assist or steering control malfunction.

STEERING

Steering system, potentially related to electric power steering (EPS) or driver-assist systems (lane keeping or steering assist). While completing a routine right-hand turn, my husband began to straighten the steering wheel when the steering system suddenly and sharply turned further right without any driver input. This caused the vehicle to strike a curb, damaging both passenger-side wheels and the front tire. There were no warning lights or indicators, and road and weather conditions were normal. The uncommanded steering input appeared to come from the vehicle itself. The incident resulted in loss of directional control and could have been severe had another vehicle, pedestrian, or cyclist been present. This behavior reflects a serious and unexpected failure in the steering or driver-assist system, posing a direct threat to driver and public safety. I reported the incident to my local Toyota dealership. I have since signed Toyota’s EDR (Event Data Recorder) consent form, and an official inspection has occurred but they haven't provided detail. They also did not make me aware the inspection was taking place and did it without coordination. They have not confirmed that this has happened before. A similar, though less severe, issue occurred previously while I was driving on the highway. As I approached a merging lane to my right, the car suddenly pulled sharply to the right, seemingly misinterpreting the lane markings or misjudging its position. There were no vehicles next to me at the time, and I was able to regain control. While it did not result in a collision, it was alarming and appears to have been a driver-assist or steering control malfunction.

ELECTRICAL SYSTEM

The air conditioner/heat pump has went out twice in 5 months. AC compressor failure poses several safety risks, including the potential for fires, refrigerant leaks leading to health hazards, and increased humidity fostering mold and mildew growth, which can worsen indoor air quality and lead to respiratory issues. Causing concern of leaking refrigerant into the cabin of the vehicle could lead to cancer and death.

UNKNOWN OR OTHER

Sparks coming out the charge port

SERVICE BRAKES

2024 BZ4x, 590 miles on ODO. Purchased the car on Sunday, 03/23/2025. Monday Morning - Turning on the Car (In my garage). I had it in "ready" while I tried to connect my Toyota app to the car, While talking to Toyota engagement for help.. (Never was able to change the primary driver on it.) The accessory lights flickered and a bell went on and off. Then the car went totally black. Toyota called a tow truck driver. He jumped the 12 volt. It gave it enough juice so I put in reverse and there was a Loud Grinding noise. "Brake System Malfunction- Take to Dealer." Tow truck loaded it up, grinding and all, took it to Toyota. There, found out the 12 volt battery died. No reported grinding when off loading or at the dealer. Toyota Dealer replaced the 12 volt battery on Monday 03/24/2025. Picked it up, drove it around about 40 miles and parked it in my garage. Parked with >80% battery on Lith battery Monday night 21:00. Sat in the Garage on Tuesday. Wednesday Morning 08:00am, 12 Volt COMPLETLY DEAD. It's back at the dealership. MY safety concern - Does this mean the Brake system will "malfunction" if the 12 volt battery isn't holding enough charge to operate the BRAKE SYSTEM?! Not sure if it means the parking brake or the actual brakes.

FUEL/PROPULSION SYSTEM

2024 BZ4x, 590 miles on ODO. Purchased the car on Sunday, 03/23/2025. Monday Morning - Turning on the Car (In my garage). I had it in "ready" while I tried to connect my Toyota app to the car, While talking to Toyota engagement for help.. (Never was able to change the primary driver on it.) The accessory lights flickered and a bell went on and off. Then the car went totally black. Toyota called a tow truck driver. He jumped the 12 volt. It gave it enough juice so I put in reverse and there was a Loud Grinding noise. "Brake System Malfunction- Take to Dealer." Tow truck loaded it up, grinding and all, took it to Toyota. There, found out the 12 volt battery died. No reported grinding when off loading or at the dealer. Toyota Dealer replaced the 12 volt battery on Monday 03/24/2025. Picked it up, drove it around about 40 miles and parked it in my garage. Parked with >80% battery on Lith battery Monday night 21:00. Sat in the Garage on Tuesday. Wednesday Morning 08:00am, 12 Volt COMPLETLY DEAD. It's back at the dealership. MY safety concern - Does this mean the Brake system will "malfunction" if the 12 volt battery isn't holding enough charge to operate the BRAKE SYSTEM?! Not sure if it means the parking brake or the actual brakes.

ELECTRICAL SYSTEM

2024 BZ4x, 590 miles on ODO. Purchased the car on Sunday, 03/23/2025. Monday Morning - Turning on the Car (In my garage). I had it in "ready" while I tried to connect my Toyota app to the car, While talking to Toyota engagement for help.. (Never was able to change the primary driver on it.) The accessory lights flickered and a bell went on and off. Then the car went totally black. Toyota called a tow truck driver. He jumped the 12 volt. It gave it enough juice so I put in reverse and there was a Loud Grinding noise. "Brake System Malfunction- Take to Dealer." Tow truck loaded it up, grinding and all, took it to Toyota. There, found out the 12 volt battery died. No reported grinding when off loading or at the dealer. Toyota Dealer replaced the 12 volt battery on Monday 03/24/2025. Picked it up, drove it around about 40 miles and parked it in my garage. Parked with >80% battery on Lith battery Monday night 21:00. Sat in the Garage on Tuesday. Wednesday Morning 08:00am, 12 Volt COMPLETLY DEAD. It's back at the dealership. MY safety concern - Does this mean the Brake system will "malfunction" if the 12 volt battery isn't holding enough charge to operate the BRAKE SYSTEM?! Not sure if it means the parking brake or the actual brakes.

UNKNOWN OR OTHER

**Report to NHTSA – 12-Volt Battery Issue in Toyota BZ4X** **Vehicle Information:** - **Make & Model:** Toyota BZ4X - **Issue:** 12-Volt Battery Drain **Description of the Problem:** I have been experiencing repeated issues with the 12-volt battery in my Toyota BZ4X. If the vehicle is not driven for one or two days, the battery depletes, requiring a jump-start to operate. I have taken the car to the dealership for inspection on two separate occasions—once in November and again recently. On both visits, the dealer was unable to identify any issues. However, despite these inspections, the problem persists. Most recently, after taking the vehicle to the dealership, the car once again failed to start the following day and required another jump-start. **Safety Concern:** This recurring battery failure presents a significant safety risk, particularly if the vehicle becomes inoperable in a remote location or in an emergency situation. The inability to start the car reliably raises concerns about potential hazards, especially in extreme weather conditions or areas with limited access to assistance. **Request for Investigation:** I urge the NHTSA to investigate this issue further, as it affects the reliability and safety of the vehicle. A resolution is necessary to ensure that the 12-volt battery functions as intended without leaving drivers stranded.