2019 Toyota Corolla

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.

Odometer Fraud. The contact purchased a 2019 Toyota Corolla. The contact stated that while attempting to register the vehicle, it was discovered that there was a mileage discrepancy. The vehicle was a dealer sale. At the time of purchase, the vehicle mileage was 45,709, and at the time of registration, it was discovered that the mileage listed on the title was 46,091. Additionally, the contact later became aware that the vehicle was a salvaged vehicle. The seller was contacted several times but blocked all communications.

NHTSA ID

11754726

Incident

Apr 4, 2023

Mileage

46,091 mi

The contact owns a 2019 Toyota Corolla. The contact stated that while driving at an undisclosed speed, the low tire pressure warning light illuminated, with several other unknown warning lights illuminated. The vehicle was taken to an independent mechanic to be diagnosed. However, the independent mechanic stated that the tire pressures were not low, and that the cause of the failure was not determined. The vehicle was not repaired. The manufacturer was not notified of the failure. The failure mileage was approximately 75,000.

NHTSA ID

11744710

Incident

Jun 17, 2026

Mileage

75,000 mi

I was driving on a two lane state road. Two vehicles we traveling in front of me in the left lane. The further vehicle in left decide to make a sudden stop at a traffic light. The silver sedan behind that vehicle was traveling too close to react appropriately. The sedan avoid the vehicle in front of it and impeded into my lane and collide with my vehicle. My airbags in my 2019 Corolla failed to deploy.

NHTSA ID

11735650

Incident

Mar 20, 2026

Premature slave cylinder failure at ~70k miles. Suddenly started leaking brake fluid profusely. Inspected and confirmed by Toyota dealership. No symptoms prior to failure. Clutch stopped functioning, unable to shift while driving. Pulled over to inspect and all of the brake fluid had leaked out. Refilled brake fluid and bled system, reservoir leaked to minimum fill line within 24 hours.

NHTSA ID

11730580

Incident

Mar 27, 2026

DESCRIPTION OF SAFETY ISSUE: The Concentric Slave Cylinder (CSC) on my 2019 Toyota Corolla Hatchback 6-speed manual failed during normal driving at around 60mph, creating an immediate and uncontrolled safety hazard. The clutch pedal depressed fully to the floor while I was shifting from 5th gear to 6th gear and the vehicle became unable to be shifted out of gear, leaving me unable to properly control vehicle speed or movement. The only way to release the transmission was to physically reach down and lift the clutch pedal up with my foot while attempting to drive. CRITICAL SAFETY CONCERN - SHARED BRAKE AND CLUTCH FLUID RESERVOIR: On this vehicle, the brake fluid reservoir and clutch hydraulic system share a single reservoir. When the CSC fails and leaks fluid, brake fluid is consumed directly from the same reservoir that supplies the braking system. A CSC failure does not only result in loss of clutch function — it results in loss of brake fluid, and with sufficient fluid loss, partial or complete brake failure. This is not a theoretical risk. This vehicle can fail in a way that simultaneously removes the driver's ability to control vehicle speed via the transmission AND reduces or eliminates braking capability — both at the same time, without warning I am requesting that NHTSA investigate this as a safety defect and consider whether a recall or service campaign is warranted given the risk of simultaneous clutch and brake failure on these vehicles.

NHTSA ID

11729790

Incident

Apr 6, 2026

6 speed manual transmission. 79K miles. Vehicle was checked at a dealer due to a sluggish clutch. Dealer found low brake fluid, but no problems with the clutch. The next day the clutch failed completely and car had to be towed off the highway. Slave cylinder for the clutch is a design flaw on these vehicles.

NHTSA ID

11728777

Incident

Mar 18, 2026

Clutch release bearing/slave cylinder failed at 29,900 miles. Without warning or unusual symptoms, clutch pedal stuck to floor and was unable to shift gears without manually pulling clutch pedal up.

NHTSA ID

11727668

Incident

Mar 22, 2026

The clutch slave cylinder in my 2019 Toyota Corolla Hatchback failed, causing brake fluid to leak out. The leaking fluid contaminated the clutch assembly, resulting in both the slave cylinder and clutch needing replacement. The failed components should be available for inspection from the repair facility upon request. The failure led to a loss of proper clutch operation, which made it difficult to shift gears and control the vehicle. This created a risk of stalling in traffic or being unable to accelerate when needed, increasing the potential for a collision, especially in busy or high-speed driving conditions. Yes, the issue was diagnosed and confirmed by the dealership. They identified the failed slave cylinder and verified that brake fluid leakage caused contamination of the clutch, requiring replacement of both components. The vehicle has been inspected by a service technician/mechanic at the Toyota dealership. Prior to the failure, there were no warning lights or dashboard messages indicating a problem. The issue appeared suddenly when the clutch began to malfunction due to the fluid leak causing me to not be able to shift gears and the clutch pedal not returning.

NHTSA ID

11727599

Incident

Mar 20, 2026

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.

Some 2021 – 2022 model year Avalon, 2018 – 2024 Camry, 2019 – 2025 model year Corolla, 2022 – 2025 model year Corolla Cross, and 2019 – 2025 model year RAV4 vehicles with A25A-FKS and M20A-FKS engines may have a MIL ON condition with one or more of the following Diagnostic Trouble Codes (DTCs) upon cold soak start up with engine coolant temperatures between 14°F – 41°F: •P030027 – Random/Multiple Cylinder Misfire Detected (Emission) Signal Rate of Change Above Threshold •P030000 – Random/Multiple Cylinder Misfire Detected •P030100 – Cylinder 1 Misfire Detected •P030200 – Cylinder 2 Misfire Detected •P030300 – Cylinder 3 Misfire Detected •P030400 – Cylinder 4 Misfire Detected

Some 2018 – 2021 model year Toyota vehicles equipped with an A25A-FKS, A25A-FXS, or M20A-FKS engine may exhibit a condition in which an “Engine Maintenance Required” message is displayed in the Multi-Information Display (MID). Additionally, the vehicle will exhibit DTC(s) P268111 (Engine Coolant Bypass Valve Circuit Short to Ground) and/or P268115 (Engine Coolant Bypass Valve Circuit Short to Battery or Open).

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.

Some 2018 – 2021 model year Toyota vehicles equipped with an A25A-FKS, A25A-FXS, or M20A-FKS engine may exhibit a condition in which an “Engine Maintenance Required” message is displayed in the Multi-Information Display (MID). Additionally, the vehicle will exhibit DTC(s) P268111 (Engine Coolant Bypass Valve Circuit Short to Ground) and/or P268115 (Engine Coolant Bypass Valve Circuit Short to Battery or Open).

Some 2021 – 2022 model year Avalon, 2018 – 2024 Camry, 2019 – 2025 model year Corolla, 2022 – 2025 model year Corolla Cross, and 2019 – 2025 model year RAV4 vehicles with A25A-FKS and M20A-FKS engines may have a MIL ON condition with one or more of the following Diagnostic Trouble Codes (DTCs) upon cold soak start up with engine coolant temperatures between 14°F – 41°F: •P030027 – Random/Multiple Cylinder Misfire Detected (Emission) Signal Rate of Change Above Threshold •P030000 – Random/Multiple Cylinder Misfire Detected •P030100 – Cylinder 1 Misfire Detected •P030200 – Cylinder 2 Misfire Detected •P030300 – Cylinder 3 Misfire Detected •P030400 – Cylinder 4 Misfire Detected