2021 Toyota RAV4 Prime

NHTSA received a petition on or about July 18, 2022, requesting that Federal Motor Vehicle Safety Standard (FMVSS) 141 be applied to all electric and hybrid vehicles operating in the United States. The petition can be reviewed at NHTSA.gov under ODI Number 11486072. FMVSS 141 establishes performance requirements for pedestrian alert sounds for motor vehicles. The standard applies to hybrid and electric vehicles that have a gross vehicle weight rating of 4,536 KG or less or are defined as low-speed vehicles. The standard became fully applicable to all such vehicles manufactured on or after March 1, 2021.On January 27, 2023, NHTSA opened Defect Petition (DP) 22-005 to evaluate the subject matter described in the petition. On June 24, 2023 and as supplemented on June 25, 2023, the petitioner notified NHTSA he was withdrawing his petition. The petitioner indicated that, based on his review of data, there is no justification for asserting potential benefits that could be derived from actions sought by my petition. Based on the petitioner's withdrawal, DP22-005 is closed. Closure of this DP does not represent a determination by NHTSA regarding the subject matter of the petition.

Observed arcing noises and strong electrical fire smell upon plugging in L2 EVSE charging cable. MIL lit, Hybrid Vehicle Charging System codes active; vehicle refused to charge afterwards. Self-diagnosed and repaired defective 6.6 kW onboard charger. See pics of clear arcing damage withing charging unit - possible fire risk.

NHTSA ID

11742590

Incident

May 4, 2026

Something needs to be done because Toyota is stalling on sending out a critical safety component that has been recalled in thousands of vehicles. It is the HV floor wire connector, when the corrosion is beyond repair, the parts have been back ordered for months. Toyota and dealerships are not approving loaner vehicles. This is a serious safety issue because: If the wire corrodes or shorts out, the vehicle can experience unexpected power loss, stalling, or complete hybrid system failure. this could happen in the middle of driving in fast, traffic, leading to serious injury or loss of life. I have been waiting since February for this part and it is still on backorder. Toyota is not taking this seriously because it’s a $10,000 part and they don’t want to pay for the thousands of people who are affected by this. My life is more important than that, as is the life of my child. I exhort you to put pressure on Toyota. Thank you.

NHTSA ID

11739499

Incident

May 1, 2026

Random windshield crack that appeared out of no where when leaving work. 4 hour time span of video shows no foul play, nobody was mowing the yard. No way anything hit it - I confirmed. Crack started to expand up and out both ways. Can run my finger along the entire crack without any surface impacts or bumps felt. First noted crack 4/29 and has expanded since.

NHTSA ID

11735889

Incident

Apr 29, 2026

Front Driver side and front passenger side door actuator has failed. Locks are non responsive to key fob or interior master switch. The door locks have to be manually unlocked with the key or by the individual in the vehicle. It is a complete safety hazard. My local Toyota dealer has quoted me $1,767 to fix the two faulty actuators. The car is 5 years old with 89,000 miles.

NHTSA ID

11735667

Incident

May 2, 2026

Sunroof exploded while driving down the freeway. Covering the occupants in glass, including the driver, this caused cuts from glass shards. This is a known issue to Toyota. They decided not to do a recall. They are lucky that the sunroof exploding did not cause a fatal accident.

NHTSA ID

11734835

Incident

Apr 30, 2026

The vehicle generated an error message "Plug In Charging System Malfunction" warning on the dash. The remedy is a Toyota T-SB-0021-21 which requires a software upgrade to fix the air fan sensor reading to the charging unit. This is only considered part of the 60 month/60,000 mile power train warranty despite it being part of the battery charging system which has a 150,000 mile warranty. It is also presumably caused by a software error Toyota has made. They should fix this at no cost to the customer, instead I was charged $215 plus tax.

NHTSA ID

11734723

Incident

Apr 28, 2026

Close the door and the rear view window shattered.

NHTSA ID

11719816

Incident

Feb 23, 2026

During snowy but manageable conditions, the brake system on my 2021 RAV4 Prime SE failed to respond, and the vehicle did not decelerate when I pressed the brake pedal. A “Pre-Collision System Malfunction” warning appeared shortly before impact. I was unable to steer away despite attempting an evasive turn. The vehicle collided with the car in front of me, and the airbags did not deploy. I was driving at a reduced speed due to snow. The vehicle ahead (a BMW SUV) began slowing. When I applied the brakes, my RAV4 Prime did not slow down at all—there was no deceleration, no ABS pulsing, and no traction control intervention. The vehicle continued moving forward as if the brakes were not engaging. At the same time, I saw a dashboard warning indicating a Pre-Collision System (PCS) malfunction. I attempted to turn the wheel to avoid the collision, but the vehicle did not respond to steering input quickly enough to prevent impact. Despite the collision, no airbags deployed. The vehicle has been regularly maintained (oil changes every 5,000 miles, new tires last year, all service intervals followed), and there were no warning lights or issues beforehand. Safety Concerns: •Complete or partial brake failure •Electronic braking or stability control malfunction •Pre-Collision System malfunction •Airbag non-deployment in a front impact •Potential systemic issue affecting Toyota hybrid/Prime models This incident caused significant fear and distress for both me and my child who was in the vehicle, and raises serious concerns about whether similar failures could occur for other owners.

NHTSA ID

11703035

Incident

Dec 2, 2025

Although the HV Floor Under Wire Harness and Rear Traction Motor Cable is covered by Toyota’s New Vehicle Limited Warranty for 3 years or 36,000 miles (whichever comes first), we at Toyota care about the customers’ ownership experience. Toyota is providing extended coverage under this Customer Support Program for repairs related to excessive corrosion to the wire harness connections at the Rear Motor Generator. Excessive corrosion can cause AM Radio Static during certain drive cycles, or the vehicle may not start.

OBSOLETE NOTICE February 27, 2026: This bulletin is no longer applicable and is now obsolete.

OBSOLETE NOTICE January 30, 2026: This bulletin is now obsolete. Please see T-SB-0001-26.

Some 2018 – 2024 model year Toyota vehicles equipped with a Premium Audio with Dynamic Navigation System require a Special Service Tool (SST) USB flash drive to update the map, points of interest, and system software.

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.

Although the HV Floor Under Wire Harness and Rear Traction Motor Cable is covered by Toyota’s New Vehicle Limited Warranty for 3 years or 36,000 miles (whichever comes first), we at Toyota care about the customers’ ownership experience. Toyota is providing extended coverage under this Customer Support Program for repairs related to excessive corrosion to the wire harness connections at the Rear Motor Generator. Excessive corrosion can cause AM Radio Static during certain drive cycles, or the vehicle may not start.