2013 Toyota Avalon Hybrid

The Office of Defects Investigation (ODI) has received a petition dated September 19, 2023 from the owner of a 2012 Toyota Prius V requesting that ODI reevaluate its decision to deny DP19-004. In the letter, the petitioner reported experiencing an unexpected and complete loss of brake power while driving, accompanied by multiple dashboard warning lights. This petition is based on the petitioner's direct experience and assessment that ODI closed DP19-004 because its prompting petition was withdrawn by that petitioner. ODI will review the work conducted during DP19-004 and a review of any additional related complaints and crashes via a new defect petition The petition and related materials can be reviewed at NHTSA.gov under the following ODI number:11553736.

NHTSA received a petition on or about July 18, 2022, requesting that Federal Motor Vehicle Safety Standard (FMVSS) 141 be applied to all electric and hybrid vehicles operating in the United States. The petition can be reviewed at NHTSA.gov under ODI Number 11486072. FMVSS 141 establishes performance requirements for pedestrian alert sounds for motor vehicles. The standard applies to hybrid and electric vehicles that have a gross vehicle weight rating of 4,536 KG or less or are defined as low-speed vehicles. The standard became fully applicable to all such vehicles manufactured on or after March 1, 2021.On January 27, 2023, NHTSA opened Defect Petition (DP) 22-005 to evaluate the subject matter described in the petition. On June 24, 2023 and as supplemented on June 25, 2023, the petitioner notified NHTSA he was withdrawing his petition. The petitioner indicated that, based on his review of data, there is no justification for asserting potential benefits that could be derived from actions sought by my petition. Based on the petitioner's withdrawal, DP22-005 is closed. Closure of this DP does not represent a determination by NHTSA regarding the subject matter of the petition.

On September 19, 2019, the Office of Defects Investigation (ODI) received a defect petition from Mr. Roger Hogan requesting that the Agency investigate and recall certain Toyota Prius, Prius PHV, Camry Hybrid and Avalon Hybrid vehicles for a brake actuator valve wear condition covered under Toyota Customer Support Programs ZJB and ZKK (subject CSP?s). In support of his request, the petitioner identified 117 NHTSA complaints allegedly related to the subject CSP condition, including 60 reporting crashes. On September 30, 2019, ODI opened Defect Petition DP19-004 to evaluate the petitioner?s request for an investigation. In August 2020, the petitioner notified the Agency that he was withdrawing his petition. Because the petitioner has withdrawn the petition, we are denying the petition as moot and no further analysis of this petition is necessary.NHTSA is authorized to issue an order requiring notification and remedy of a defect if the Agency?s investigation shows a defect in the design, construction, or performance of a motor vehicle that presents an unreasonable risk to safety. 49 U.S.C. ?? 30102(a)(9), 30118. Because the petitioner has with withdrawn the petition, the petition is denied as moot. This action does not constitute a finding by NHTSA that a safety-related defect does not exist. The Agency notes that it is not required to receive a defect petition prior to opening a defect investigation and will take further action if warranted by future circumstances.

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.

The contact owns a 2013 Toyota Avalon Hybrid. The contact stated that several instrument cluster warning lights were illuminated. The vehicle was taken to the local dealer who informed the contact that they were unable to determine the cause of the failure. The vehicle was not repaired. The vehicle was taken to an independent mechanic who informed the contact that the vehicle was a hazard and could catch on fire. The manufacturer was notified however, no further assistance was provided. The approximate failure mileage was 98,000.

NHTSA ID

11445406

Incident

Jun 1, 2020

Mileage

98,000 mi

TL* THE CONTACT OWNS A 2013 TOYOTA AVALON HYBRID. WHILE DRIVING APPROXIMATELY 25 MPH, THERE WAS AN ABNORMAL SOUND COMING FROM THE PASSENGER SIDE OF THE VEHICLE AND THE CONTACT NOTICED THAT THE PASSENGER SIDE EXTERIOR MIRROR HAD SHATTERED. THE MIRROR WAS NOT STRUCK BY ANY FOREIGN OBJECTS. THE VEHICLE WAS TAKEN TO JOHN O'NEIL JOHNSON TOYOTA (LOCATED AT 2900 MS-39, MERIDIAN, MS 39301, (888) 781-0044) WHERE IT WAS DIAGNOSED THAT THE MIRROR AND WIRING HARNESS NEEDED TO BE REPLACED. THE VEHICLE WAS REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 43,000.

NHTSA ID

11252055

Incident

Aug 20, 2019

Mileage

43,000 mi

WHEN IT RAINS HEAVILY (WITHIN THE TWO MONTHS I HAVE OWNED IT), THE ROOF AND/OR SUNROOF LEAKS CAUSING WATER DAMAGE IN MULTIPLE AREAS OF THE ROOF. THE DEALERSHIP CANNOT FIND A CAUSE AFTER THE INITIAL SUNROOF DRAIN WAS CLEARED.

NHTSA ID

11221582

Incident

May 6, 2019

WHEN I PUT THE CAR IN REVERSE, THERE IS A VERY LOUD GRINDING NOISE AS THE RETRACTABLE REAR WINDOW SCREEN TRIES TO GO UP. WHEN THE CAR IS PUT IN GEAR THERE IS A DIFFERENT GRINDING NOISE. THE SCREEN HAS FROZEN IN VARIOUS STAGES OF UP OR DOWN, BUT NOW IS STUCK DOWN, OBVIOUSLY TRYING TO RAISE. ACCORDING TO MANY POSTS ONLINE, INCLUDING SOME FROM TOYOTA DEALERSHIPS, THIS HAS BEEN AN ONGOING PROBLEM FOR OVER 10 YEARS. IT IS A SAFETY PROBLEM AT NIGHT WHEN THE SCREEN HAS BEEN STUCK IN THE UP POSITION AND IT IS DIFFICULT TO SEE OUT. IT IS ALSO A SAFETY PROBLEM BECAUSE THE NOISE IS VERY LOUD AND DISTRACTING. I HAVE TAKEN IT TO TWO DIFFERENT TOYOTA DEALERS WHO SAY IT WILL COST $1,600 TO REPLACE, BUT IT WOULD ONLY BE GUARANTEED FOR 1 YEAR. THE FUSE CAN'T BE REMOVED TO DISABLE IT AND STOP THE NOISE BECAUSE IT WILL AFFECT THE CRUISE CONTROL AND THE BLINKERS. I WANT THE NOISE SILENCED. TOYOTA NEEDS TO FIX THIS ISSUE THROUGH A WARRANTY EXTENSION OR RECALL.

NHTSA ID

11218055

Incident

May 1, 2019

HEADLIGHTS BLOW OUT FREQUENTLY AND NEED REPLACING.

NHTSA ID

11099094

Incident

May 31, 2018

Mileage

65,797 mi

REAR WINDOW SHADE WILL NOT RETRACT. STAYS IN UP POSITION ALL THE TIME. HARD TO SEE AT NIGHT. DEALER SAYS THERE HAS BEEN ALOT OF SHADES THAT QUIT FUNTIONING. NOT COVERED UNDER WARRANTY. $1700 REPAIR IF WANT DONE. CAN'T EVEN DISABLE SO IT WILL RETRACT AND STAY DOWN.

NHTSA ID

11039357

Incident

Aug 15, 2017

Mileage

58,000 mi

AVALON RECALL NO 15V728. HAD THE RECALL "REMEDY" PERFORMED ON MY CAR 09/07/16 (WAS HAVING NO ISSUE WITH MY CAR BEFORE THE RECALL) AND NOW THE PCS WARNING BUZZES AND LIGHTS UP, AND THE RED BRAKE! MESSAGE LIGHTS UP EVERY TIME I DRIVE THE VEHICLE! CONTACTED TOYOTA CORPORATE OFC (CASE #1609142106 & #1611100472) TO REPORT THE ISSUE HAS NOT BEEN RESOLVED, AND EXPRESS MY FEAR THAT THE SYSTEM WILL NOW NOT WORK WHEN IT IS SUPPOSED TO, BUT THE "CASE MGR" (CORY CARTER) STATED "THERE IS NOTHING ELSE THEY CAN DO FOR ME", AND ADVISED ME TO "SEEK OUTSIDE ASSISTANCE FOR ANY ADDITIONAL HELP'. I ASKED IF THIS MEANT SEEKING AN ATTORNEY, TO WHICH HE REPLIED "YES". I FEEL MY CAR IS NOW UNSAFE, AND TOYOTA COULD CARE LESS!!

NHTSA ID

10926001

Incident

Sep 7, 2016

TL* THE CONTACT OWNS A 2013 TOYOTA AVALON HYBRID. THE CONTACT RECEIVED A RECALL NOTIFICATION FOR NHTSA CAMPAIGN NUMBER: 15V728000 (FORWARD COLLISION AVOIDANCE); HOWEVER, THE PARTS NEEDED WERE NOT AVAILABLE. THE CONTACT BELIEVED THAT THE MANUFACTURER EXCEEDED A REASONABLE AMOUNT OF TIME TO PROVIDE THE RECALL REPAIR. THE DEALER INSPECTED THE VEHICLE AND PERFORMED THE TEMPORARY REMEDY. THE MANUFACTURER WAS MADE AWARE OF THE DELAY. THE CONTACT HAD NOT EXPERIENCED A FAILURE.

NHTSA ID

10888507

Incident

Nov 30, 2015

OBSOLETE NOTICE February 13, 2026: This bulletin is now obsolete. Please see T-SB-0009-26.

This bulletin includes basic procedures for performing a rescue charge on Ni-MH high voltage (HV) batteries. This bulletin should be used in conjunction with the applicable model and model year Repair Manual while performing a rescue charge. The GRX-5100 should be used wherever the Repair Manual references the Toyota Hybrid System (THS) charger.

Some 2005 – 2026 Toyota vehicles that have undergone water intrusion may exhibit a condition in which a musty odor is present. Follow the procedures in this bulletin to remediate the odor and address this condition. The purpose of this Service Bulletin is to provide general guidelines and procedures for odor remediation. This Service Bulletin provides a guide on how to prepare and treat the interior of the vehicle for odor remediation. Refer to the applicable model and model year Repair Manual and the EPA (Environmental Protection Agency) website for the most up-to-date safety and precautionary guidelines.

The air conditioning dye injection tool kit has been developed to aid in identifying the location of air conditioning refrigerant leaks. The procedures outlined in this Service Bulletin aid in locating, inspecting, and repairing refrigerant leaks.

Acid rain results from rainwater or other airborne moisture that become acidic due to industrial chemical impurities in the atmosphere. If these acidic compounds settle on an exposed vehicle, especially the horizontal areas such as the hood, roof, and decklid, significant damage to the painted surfaces can occur. Acid rain damage can typically be identified on vehicles by the presence of stains on the paint surface that resemble hard water spots. Unlike water spots however, acid rain damage cannot be removed by regular washing procedures. Also, because acid rain can etch and soften the paint, normal buffing or polishing repair procedures should not be attempted. This can cause further damage and result in visible depressions in the paint surface. The following are the three major categories of acid rain damage: •Minor damage: requires only buffing to repair. •Moderate damage: usually requires neutralizing, color sanding, and buffing. •Severe damage: extending beyond 1/2 mil of clearcoat on a pearl, metallic, or solid color, requires neutralization, sanding, and repainting. In cases where acid rain damage is minor, neutralization and buffing with a liquid-type paint finessing product may provide an adequate repair. Only specially formulated products outlined in this bulletin should be used for that purpose. Unfortunately, other than minor damage, there is no simple method of determining the actual extent (depth) of acid penetration other than color sanding a representative affected area until there is no visible etching or depressions, followed by measuring the amount of paint removed with either a magnetic or digital-type film thickness gauge. The procedures in this bulletin are intended for use by qualified body/paint technicians and should not be attempted by inexperienced personnel. It is the dealer’s responsibility to protect and maintain the quality of the vehicle’s paint finish after receipt at the dealership prior to the first sale. Perform frequent vehicle washing, as often as daily, during high heat and humidity periods to minimize the potential for paint damage due to acid rain exposure. This is especially important in geographical areas known for high frequency and concentration of acid rain and industrial fallout.

To prevent brake rotor rust from forming during transportation and storage, wheel film will be used instead of a cardboard type of anti-rust cover. The purpose of the wheel film is to shield the disc brake rotor from weather elements and initial rust before the vehicle is delivered to the customer. Consequently, the film should remain on the wheel for as long as possible.