2012 Toyota Avalon

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.

While entering the highway on ramp, as I accelerated and turned on the left turn signal, the engine stopped. The steering became very hard. I stopped, put the transmission in park and started the engine, with no problems. This is the second time in3 months this has happened when turning to the left, and activating the turn signal. In both cases, the auto headlight dimming warning lite came on. The car is well maintained, and has never been damaged in any way. The weather was clear.

NHTSA ID

11520588

Incident

May 4, 2023

The contact owns a 2012 Toyota Avalon. The contact stated that while it was hot outside, or whenever there was direct sunlight on the dashboard, the dashboard would become very sticky. The contact stated that the glare on the windshield from the reflection of the dashboard made it very difficult to see out the windshield. The contact stated that he contacted the dealer, and manufacturer about the failure, and was informed that previously there was a recall for the failure however, the recall had expired. The contact contacted the NHTSA after researching the failure. The failure mileage was 50,000.

NHTSA ID

11460724

Incident

Apr 7, 2022

Mileage

50,000 mi

There is a rear windshield shade that comes up automatically during a bright or hot day. It has a button to manually bring it up or down also. Just last month the gear inside the shade is broken and it does not come down. If I manually put it down it will come up automatically when driving, causing a loud noise distracting the driver even though, the driver has not pressed the button to pull it up. Now it is stuck in up position causing loud noise when reversing. And the biggest safety issue that I see is the night driving. Since the shade is up and I cannot make it go down, the visibility in the rear view mirror is very poor or nothing. There is no way for the driver to let it stay in the down position and driving on overcast days or night time is a challenge with no visibility of vehicles behind you.

NHTSA ID

11449358

Incident

Dec 20, 2021

REAR SUNSCREEN REMAINS IN UP POSITION, WHEN LOWERED IN REVERSE, IT MAKES A LOUD GRINDING NOISE. HAVING TO DRIVE AT NIGHT PRESENTS A PROBLEM WITH VISIBILITY WHEN THE SUNSCREEN REMAINS IN THE UP POSITION.

NHTSA ID

11322510

Incident

Apr 25, 2020

Mileage

117,000 mi

TL* THE CONTACT OWNED A 2012 TOYOTA AVALON. THE FRONTAL AIRBAGS FAILED TO DEPLOY WHEN AN 18 WHEELER COLLIDED INTO THE VEHICLE WHILE TRAVELLING AT 65 MPH. THE CAUSE OF THE FAILURE WAS UNKNOWN. THE VEHICLE WAS DESTROYED AND THE DRIVER AND PASSENGER WERE HOSPITALIZED WITH SPINAL INJURIES AND BRUISES. THE CONTACT STATED THAT WHILE TRAVELING APPROXIMATELY 65 MPH, AN 18 WHEELER STROKE THE VEHICLE IN THE MIDDLE REAR WHEN ATTEMPTING TO SWITCH LANES. NONE OF THE FRONTAL AIR BAGS DEPLOYED. THE POLICE WAS PRESENT AND A REPORT WAS ISSUED. THE VEHICLE WAS NOT TAKEN TO THE DEALER FOR DIAGNOSTICS. THE CONTACT ALSO RECEIVED A RECALL NOTIFICATION FOR NHTSA CAMPAIGN NUMBER: 18V569000 (AIR BAGS, SEAT BELTS) THE VEHICLE WAS TOWED TO AN IMPOUND LOT. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE VEHICLE WAS DESTROYED AND TOTALED. THE APPROXIMATE FAILURE MILEAGE WAS 71,000.

NHTSA ID

11316549

Incident

Nov 19, 2018

Mileage

71,000 mi

ANOTHER DRIVER RAND A RED LIGHT AND I (T-BONED HIS PASSENGER SIDE) WAS IN A HEAD ON COLLISION. I WAS BREAKING AT THE TIME, BUT STILL IMAGINE I HIT HIM AT BETWEEN 30-40 MPH. THE FRONT END CRUMPLED AS EXPECTED BUT THE AIRBAGS DID NOT DEPLOY. FIREFIGHTERS CUT POWER TO PREVENT THE AIRBAGS FROM DEPLOYING UNEXPECTEDLY AFTERWARDS. A CHECK PASSENGER AIRBAG LIGHT HAD COME ON IN RECENT DAYS THAT I DID NOT GET FIXED BEFORE THE ACCIDENT, BUT IT SHOULD NOT HAVE AFFECTED THE DRIVER SIDE AIRBAG I EXPECT. LIBERTY MUTUAL IS CURRENTLY IN POSSESSION OF THE CAR (THEY DEEMED IT A TOTAL LOSS).

NHTSA ID

11269414

Incident

Oct 2, 2019

Mileage

115,000 mi

TL* THE CONTACT OWNS A 2012 TOYOTA AVALON. THE CONTACT STATED THAT THE VEHICLE STARTED ON ITS OWN. THE MOTOR WAS EXTREMELY LOUD AND WAS A DISTRACTION TO THE DRIVER. WHEN THE CONTACT WOULD TURN OFF THE ENGINE, IT WOULD SOMETIMES RESTART ON ITS OWN. THE CONTACT CALLED BOWLING GREEN TOYOTA (2398 SCOTTSVILLE RD, BOWLING GREEN, KY 42104, (270) 843-4321) AND WAS INFORMED THAT A NEW REAR SHADE MOTOR WAS NEEDED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE AND DID NOT ASSIST. THE FAILURE MILEAGE WAS 37,000.

NHTSA ID

11221166

Incident

Apr 17, 2019

Mileage

37,000 mi

MY VEHICLES AIRBAGS DID NOT DEPLOY I WAS HIT BY AN 18 WHEELER AT A HIGH RATE OF SPEED. THE VEHICLE HAD AT LEAST 2 REAR END HITS BY THIS 18 WHEELER ESTIMATED AT A SPEED IN EXCESS OF 25 MILES PER HOUR FASTER THAN MINE (I WAS GOING AT 70MPH NORTHBOUND ON US 75, NINE MILES SOUTH OF TULSA OKLAHOMA ON A SUNNY MONDAY AT 3PM). THE STREET WAS DRY. THE TRUCK INITIALLY HIT ME ON MY REAR AND ON MY LEFT REAR QUARTER. I WAS SPUN IN FRONT OF THE TRUCK AND HE HIT ME AGAIN ON THE REAR QUARTER AND THE BUMPER AND SPUN ME IN THE OPPOSITE DIRECTION AND THEN PUSHED INTO THE GUARDRAIL AT AN ESTIMATED 40+ MPH. THE AIRBAGS DID NOT DEPLOY FOR ANY OF THE THREE COLLISIONS (TWO IN THE REAR AND ONE IN THE FRONT).

NHTSA ID

11161898

Incident

Nov 19, 2018

Mileage

70,000 mi

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.

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.

The condition known as acid rain is caused by airborne chemicals or particles in the atmosphere, which mix with rainwater, nighttime dew, or high humidity to form acidic compounds. If these contaminants settle and remain on a painted vehicle surface, especially the horizonal areas of the hood, roof, and decklid, significant damage can occur. This damage is the result of actual etching of the paint and appears as pitting or water spots. As acid rain droplets on the vehicle surface evaporate, the concentration strength of the acid increases, causing deeper and more rapid damage. This evaporation and corrosive action also occur more rapidly on dark colored cars as direct sun heat increases. 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. In areas known for high frequency and/or concentration of acid rain, frequent vehicle washing during high heat or humidity periods will minimize the potential for paint damage caused by acid rain. It is further recommended that either reverse osmosis or deionized water be used to prevent water spotting.

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.

Toyota vehicles are currently protected with RapgardTM protective film designed to protect the horizontal painted surfaces. This material protects from acid rain, environmental fallout, and rail contamination. Follow the Removal Procedure in this bulletin to remove the RapgardTM protective film within 90 days from initial application.

Vehicles may occasionally be subjected to contamination by airborne iron particles shed from railroad tracks, train wheels, exposure to heavy machinery facilities, grinding, welding, etc. This type of contamination can be identified by the presence of small, red or brown particles on the paint surface. These particles are often difficult to see on dark color paints but can be easily felt when brushing a hand across horizontal body surfaces such as the hood, roof, or deck lid. Follow the Repair Procedure in this bulletin to clean vehicles that may have been subjected to contamination by airborne iron particles such as rail dust during rail transportation or extended storage near industrial areas.