2023 Toyota BZ4X

While driving on the highway under normal conditions with no road hazards present, the engine under cover (part #51441-42210) detached from my vehicle and the bumper clips broke, causing both the under cover and bumper to become damaged and requiring replacement. There was no collision, no debris, no pothole, or any other road hazard involved. The failure occurred solely under routine highway driving conditions. Upon taking the vehicle to my Toyota dealership, the service team acknowledged this is a known and recurring issue with the bZ4X model. Research and owner forums confirm multiple 2023 bZ4X owners have experienced the identical failure — undercarriage cover and bumper detachment under normal driving and rain conditions. Toyota dealers have repeatedly told affected owners ‘this happens all the time,’ yet Toyota refuses to cover repairs under warranty, claiming it is not a manufacturing defect. I believe this represents a systematic design or manufacturing defect in the 2023 Toyota bZ4X. The undercarriage cover and bumper mounting system fails under normal driving conditions, which poses a safety risk to the driver and other vehicles on the road. I am requesting a formal investigation into this issue and urge NHTSA to consider a recall to protect other bZ4X owners.

NHTSA ID

11733142

Incident

Apr 18, 2026

The contact owns a 2023 Toyota BZ4X. The contact stated that the vehicle was awaiting a recall repair. The dealer informed the contact that the electrical HVAC compressor needed to be replaced as part of the recall repair; however, the part was on back order. The vehicle was taken to the dealer, but the recall repair was not completed. The manufacturer was notified of the failure. The approximate failure mileage was 117,000.

NHTSA ID

11728838

Incident

Sep 25, 2025

Mileage

117,000 mi

The contact owns a 2023 Toyota BZ4X. The contact had attempted to use the defroster; however, the blower was not blowing hot air onto the windshield. The contact had received notification of NHTSA Campaign Number: 25V577000 (Visibility); however, when the dealer was contacted to schedule a recall repair, the contact was informed that the part to do the recall repair was on national back order. The contact called another dealer and the manufacturer, and was informed by both that the part was on national back order. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The failure mileage was approximately 55,000.

NHTSA ID

11708823

Incident

Dec 15, 2025

Mileage

55,000 mi

The contact owns a 2023 Toyota BZ4X equipped with Goodyear Tires, Tire Line: Electric Drive 2, Tire Size: 215/50/R20, DOT Number: (N/A). The contact stated that while driving at various speeds above 50 MPH, the vehicle experienced severe shaking and abnormal vibration. The vehicle was taken to the local service center who determined that the foam pad inside the tire had malfunctioned. The foam was replaced, and the tires were balanced, but later the same failure reoccurred on the rear passenger’s side tire. The vehicle was taken to the local dealer for repair. No further information was available. The manufacturer was not notified of the failure. The failure mileage was unknown. The VIN was not available.

NHTSA ID

11708384

Incident

Dec 1, 2025

Premature and abnormal tire wear on my 2023 Toyota bZ4X, confirmed by two independent tire shops, despite consistent Toyota dealer maintenance every 6,000 miles. Beaverton Toyota dealer dismissed the condition as “normal,” but both [XXX] and Discount Tire documented unsafe tire wear caused by alignment. --- Details of Problem: Vehicle serviced exclusively at Toyota dealer (Beaverton Toyota, OR) every 6,000 miles, with multipoint inspections and rotations. On 9/22/25, Toyota dealer inspected the vehicle and reported that alignment and tires were “normal.” On 9/25/25, [XXX] inspected the vehicle and documented severe outside shoulder wear on the right-side tires. They recommended immediate tire replacement for safety. Alignment was also adjusted at that time to bring values into balance (report attached). On 9/27/25, Discount Tire replaced all four tires at 27,562 miles. Their written notes confirm edges were worn on all four tires due to alignment (right side more prominent). They declared the tires unsafe for continued use and recommended full replacement. Safety Concern: This abnormal alignment-related wear created unsafe driving conditions well before the rated tire life (55,000 miles). Uneven edge wear and shoulder failure increase the risk of blowouts, hydroplaning, or sudden loss of control. Attachments available: Toyota dealer report stating “normal” Les Schwab alignment printout and written safety note Discount Tire invoice with technician safety comments Tire photos (all four corners) Full Toyota dealer service history INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11690353

Incident

Sep 22, 2025

UNKNOWN , 11/26/2024 car in garage would not start, car was tow to Toyota and Toyota replaced the battery. then on 02/06/2025 vehicle was in garage and would not start and vehicle was tow again to Toyota dealer. Where dealer replaced 12 volt battery at 5,283 miles. And told us to put a battery charger on the battery.

NHTSA ID

11666165

Incident

Feb 6, 2025

I drove the car at 40mph through about 2 inches of standing water. This caused the undercarriage splash plate to become loose. It has not fallen off, but it will need to be repaired. The streets sometimes flood and none of the cars I’ve owned ever had this happen.

NHTSA ID

11650708

Incident

Feb 27, 2025

AC Compressor. The dealer is saying I need to repair the AC compressor. When this happened my heater and mileage weren't showing and a lot of message errors were showing.

NHTSA ID

11649065

Incident

Mar 14, 2025

Toyota is conducting a noncompliance equipment recall involving certain Rear Combination Lamp service parts for Toyota bZ4X sold from December 2023 to November 2025 in the U.S. Approximately 80 service parts are involved in this recall. The subject rear combination lamp service parts were sold in the U.S. even though they were intended for an overseas market. These parts do not meet a federal safety standard because they have a side marker reflector instead of a side marker lamp. In the absence of light reflecting off the reflector, this can reduce the ability of other road users to identify the rear of the vehicle from the side, potentially increasing the risk of a crash.

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.

Model Year 2023-2025 bZ4X vehicles have charge ports that use the CCS standard. This program is for lessees and owners of these vehicles to receive 1 complimentary NACS Charging Adapter per vehicle to enable charging at stations using the NACS standard.

TECHNICAL INSTRUCTIONS FOR 25TC03 REPROGRAMMING FOR FORWARD RECOGNITION CAMERA CERTAIN 2023 COROLLA CROSS 2023 COROLLA CROSS HV 2023 Bz4x

Some ECUs can set a DTC that is common with other ECUs. This can lead to accidental use of the wrong repair manual when diagnosing these type of DTCs.

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.