2021 TOYOTA RAV4 PRIME

ELECTRICAL SYSTEM:PROPULSION SYSTEM:DC/DC CONVERTER

Toyota Motor Engineering & Manufacturing (Toyota) is recalling certain 2021-2022 RAV4 Prime and 2022 Lexus NX450h+ plug-in hybrid electric (PHEV) vehicles. The electric current rectifying module contained within the DC-DC converter may have been damaged during production, which can result in an electrical short-circuit.

Risk: A short circuit can cause the DC-DC converter to overheat, increasing the risk of a vehicle fire.

ELECTRICAL SYSTEM:PROPULSION SYSTEM:HYBRID MANAGEMENT:POWER CONTROL UNIT/MODULE (HPCU)

Toyota Motor Engineering & Manufacturing (Toyota) is recalling certain 2021 RAV4 Prime Plug-In Hybrid vehicles. During certain cold weather driving conditions, while driving in EV Mode, the hybrid vehicle control engine control unit (HEV ECU) software may cause the hybrid system to shut down if the accelerator is rapidly pressed to further accelerate the vehicle, resulting in a stall.

Risk: An engine stall increases the risk of a crash.

SERVICE BRAKES

The car has a grinding sound and a brake slipping feeling that occurs while traveling and braking over rough pavement. It does not happen consistently, but it does happen fairly regularly (every 2-4 weeks). Note, the grinding sound can range from subtle to quite loud, depending on bump/timing of braking. This has been happening since I purchased the car and continues to happen, which is why I put today's date as the incident date, and I have been bringing it up with the Toyota maintenance department at most maintenance appointments. Their shop manager has driven it and thought I was mistaking it for the ABS activating. I have driven it with him, ABS has activated, and when he pointed it out to me, I have let him know that what is happening is definitely something different than the ABS activating. I have tried to find a location to show them to replicate it with the service center, but it happens randomly on rough patches. For example, it happened on a spot near the dealership that I thought I could use to show them, but when I drove over the same area again and braked, nothing happened. So, I have not been able to replicate this with the service center, but it is most certainly happening. I have notified Toyota through their consumer contact system that this issue is going on and they said Toyota tracks issues like this. However, no resolution has been offered. Other Toyota Rav4 Prime owners of the same year have experienced this (see [XXX] and [XXX] ). Although the maintenance manager was stumped, he said at a recent visit that another Prime owner voiced the same type of thing happening. Toyota needs to investigate to determine what the issue is and remedy the issue. I am concerned this could lead to a larger issue and is a safety recall issue that warrants immediate attention. It does not seem that Toyota is taking this seriously. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

UNKNOWN OR OTHER

On July 24th, I experienced sudden unexpected acceleration with my 2021 Toyota Rav4 Prime XSE (41,600 miles) while driving in the electric mode. I was lining myself up to reverse into my garage and as I paused to switch gears to reverse, the car suddenly accelerated full-speed towards my neighbor's house. I slammed the brakes but that had little effect. The car slammed into the house, through the garage door and my car was only stopped when hitting an SUV parked in the garage, pushing it forward about 2 feet. No air bags were deployed, the collision detection system on the vehicle did not seem to work and tire marks from my braking were visible from the middle of the road. I have found a number of very similar incidents with Toyota cars described online. Cars were often turning into parking spaces at slow speeds and ended up accelerating into lamp posts or buildings. If there hadn't been a car parked in the garage, I can't imagine what might have happened as the car was probably going 35 mph+ upon impact. There were no warning lights and the collision shop informed me that there were no diagnostic codes when they downloaded the computer.

FORWARD COLLISION AVOIDANCE: AUTOMATIC EMERGENCY BRAKING

Upon entering a light controlled intersection at a relatively slow speed (probably less than 20 mph} on wet pavement, an oncoming car suddenly made a left turn directly in front of me. I applied the applied the breaks hard and slid into the passenger side of the turning vehicle. The ABS system did not function. The air bag did not deploy. At the moment of the collision my speed was reduced and I do not know the threshold for airbags to deploy, but this was a direct front end collision. I was able to brace myself and was not injured. I am not claiming the airbag malfunctioned as the speed at the moment of impact was not high. However, I have complained to the Toyota dealer service department almost since the car was new, that the ABS does not function. They have repeatedly told me that it is fully operational based only on the fact that the system registers as "on." Being "on" does not mean it is functioning. Questions: What component failed? ABS and possibly airbag How was my safety at risk? Non functioning ABS resulting in a potentially preventable accident Has the problem been confirmed? Yes, byt the dealer though they claim the sliding of the car is due to old tires. However, the tires are withing the legal limist for tread depth and I have complained about the problem since the car and the tires were nearly new. Has the vehicle been inspected? yes, byt the Toyota dealer and an independent Toyota crash inspector Were there any warning lights etc? No

SERVICE BRAKES

Upon entering a light controlled intersection at a relatively slow speed (probably less than 20 mph} on wet pavement, an oncoming car suddenly made a left turn directly in front of me. I applied the applied the breaks hard and slid into the passenger side of the turning vehicle. The ABS system did not function. The air bag did not deploy. At the moment of the collision my speed was reduced and I do not know the threshold for airbags to deploy, but this was a direct front end collision. I was able to brace myself and was not injured. I am not claiming the airbag malfunctioned as the speed at the moment of impact was not high. However, I have complained to the Toyota dealer service department almost since the car was new, that the ABS does not function. They have repeatedly told me that it is fully operational based only on the fact that the system registers as "on." Being "on" does not mean it is functioning. Questions: What component failed? ABS and possibly airbag How was my safety at risk? Non functioning ABS resulting in a potentially preventable accident Has the problem been confirmed? Yes, byt the dealer though they claim the sliding of the car is due to old tires. However, the tires are withing the legal limist for tread depth and I have complained about the problem since the car and the tires were nearly new. Has the vehicle been inspected? yes, byt the Toyota dealer and an independent Toyota crash inspector Were there any warning lights etc? No