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.

Cruise Contol Quit. Discovered: The Air bag - Clockspring Assembly/Spiral Cable: R&R clock spring assembly has developed an open circuit causing the SRS light to illuminate as well as loss of function of the steering wheel buttons per Heyward Allen Toyota, Athens, Georgia. Diagnostic completed 10/27/26. I see that this has been a recall on prior Toyota Corolla models. Because they have not recalled this ... I must pay $1137 to have it repaired! It's my understanding that when this is not working, the airbag may not engage during an accident and other issues of braking, steering, and the collision assistance mechanisms may also fail.

NHTSA ID

11774275

Incident

Oct 19, 2026

The weekend of April 3rd, I was driving down a two lane road. There was a dip in the road that lead me to overcorrecting. I had then spun out 2 times, and flew me over a ditch, to smack down on to all 4 tires and slide into a duke energy pole. The airbags didn’t deploy at all. With the incident and the areas affected, the airbags should have deployed.

NHTSA ID

11769495

Incident

Apr 3, 2026

The contact owns a 2019 Toyota Corolla. The contact stated that while driving at an undisclosed speed, the clutch was depressed; however, the clutch system failed to operate as intended. The contact stated that the clutch was stuck to the floorboard. The contact stated that due to the failure, there was an excessive amount of clutch fluid leaking onto the ground. The vehicle was towed to the residence. The contact stated that the failure was a known failure. The manufacturer was contacted by phone and a case was filed. The failure mileage was approximately 104,000.

NHTSA ID

11766729

Incident

Sep 22, 2026

Mileage

104,000 mi

Component that failed was the CSC Concentric Slave Cylinder. I went to press the clutch and it stuck to the floor. I checked for leaks in the cabin beneath the clutch and it was dry. I then proceeded to check the reservoir and saw that it needed fluid. I managed to get it to a nearby convenience center to purchase and fill the reservoir when that did not work I called a tow truck to move it to an auto repair shop. This put others at risk, should the clutch have remained in neutral I would have, and or all the break fluid would have leaked and i would have been without brakes since the clutch and break share a reservoir. This issue could have caused serious life threatening injuries not only to myself but others had there been an accident. Thankfully this took place at 4 am before other drives were out and about for the morning commute. The component has since been looked at by an independent service center. There were no warning lamps or messages prior to the issue. the vehicle currently has roughlty 84,000 miles.

NHTSA ID

11764719

Incident

Sep 16, 2026

Slave cylinder on clutch failed and leaked fluid in to clutch and flywheel. Clutch pedal would not rebound after being pressed in to shift gear, stuck in middle of road trying to get vehicle in first gear. Had vehicle towed to dealership, estimate of $5800 to repair. Apparently this is a known problem with this manual transmission, many others have experienced similar failure at around 60,000 miles.

NHTSA ID

11763432

Incident

Sep 3, 2026

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

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