2023 Toyota BZ4X Problems

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.

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.

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.

235/50/R20. Found driver side rear tire completely flat in personal garage yesterday morning and passenger front tire had low psi warning on as well. Used the fix-a-flat kit that came with my car to fill driver rear and able to get to shop. Car/tires have 5000 miles on them. Tire shop could not find anything wrong with the driver rear tire but stated a puncture was found in passenger front tire well and did patch that. I see this has been reported before on a Toyota Bz4x same year and same tire with mileage the same as well. I am concerned this could be an issue going forward and am scared to drive this car now any distance especially since there is no spare and I have to purchase a replacement cylinder for the fix-flat.

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.

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.

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.

For the 6th time, the car is without power. It will not start although the starter battery was changed by the dealer on 5/28/24. The EV battery does not show any power. This is the 6th time that car will not start and without power. It was bought brand new on 1/1/2023.

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)

Toyota re-installed the accessory wheel locks that does not meet the design requirements of the new hub bolts per FAQ page 1 of 2; Q2B of this SAFETY RECALL 22TA06 – Remedy Notice. https://static.nhtsa.gov/odi/rcl/2022/RCMN-22V444-6442.pdf and Critical Note at the bottom of page 8 on the attached "BZ4X Fix" document.

Twice now on highways in medium rainfall, with lots of water on the road and a lot of spray, the assisted cruise control has failed to identify a vehicle in the lane in front of it, and continued to accelerate towards braking vehicles. One such occasions I was within 3-4 car lengths of the vehicle in front of me.

I submitted this form earlier, but I’m unsure whether it went through. If this is a duplicate, please disregard. An incident of sudden, unintended acceleration occurred while pulling into a gravel parking area on a hillside at dusk. While turning, the vehicle suddenly lunged forward and struck a tree stump. It would have been avoided without the sudden acceleration. The driver slammed on the brakes, and the vehicle came to rest right at the edge of a downward slope. Five seconds earlier, and a family member, who had come out of the house to show where he wanted the car parked, could have been killed, or seriously injured. The car was towed to Toyota Of Erie, where it was inspected by a corporate inspector. It remains there until a decision is made. The adaptive cruise control, which was used on the trip, had been canceled, and the brakes were used several times after exiting the freeway. There was apparently no warning from the front camera and the collision avoidance system about the tree stump, though the driver had seen it prior to making the turn. The incident happened very quickly, but there was no noticeable red warning flashing on the screen. This time there is only damage to a car fender, and a tree stump. What about next time? Suppose the vehicle is slowing into a parking space, there is a child exiting nearby van and the car suddenly accelerates? No thanks!!! This problem needs to be solved! The floor mats in the BZ 4X are secured to the floor so they are not an issue. The driver of the vehicle can play an instrument with foot pedals and is therefore very aware of foot placement-so operator error is not the problem. Perhaps there is just too much autonomous driving technology and software layered over the basic EV platform. Can’t we just have the choice of a basic EV until these other problems are worked out? I signed up to be a pioneer in the adoption of electric vehicles, but not a guinea pig for autonomous driving.

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)

On [XXX] I was involved in a collision with another vehicle on [XXX] , while driving my 2023 Toyota bZ4X. Despite the impact's severity, the airbags in my vehicle did not deploy, even though the other vehicle’s airbags did, suggesting that the impact was sufficient to trigger airbag deployment in similar conditions. After the accident, the Toyota app displayed a warning message indicating that the airbags required inspection, raising concerns about a potential malfunction in the airbag system. The failure of the airbags to deploy posed a significant risk to my safety, as the airbags are a critical safety feature designed to reduce injury in collisions. The vehicle has not yet been inspected by Toyota or a certified service center to determine the cause of the airbag failure. Prior to the collision, there were no visible warning lights or error messages on the dashboard indicating any issues with the airbag system. The vehicle is available for inspection upon request. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)