2015 Toyota RAV4

The Office of Defects Investigation (ODI) opened a Preliminary Evaluation (PE) to understand the contributing factors and frequency of vehicle fires originating from the battery region of the engine compartment in Model Year (MY) 2013-2018 Toyota RAV4 vehicles on 25 February 2021. At the time of opening, ODI attributed eleven allegations and additional EWR events to this PE. PE21005 focused on replacement batteries installed in the subject vehicles. No reported fire event identified in PE21005 involved the originally supplied 12V battery. The reported fires took place in vehicles known to contain aftermarket batteries or whose age exceeded the expected life of the original equipment battery. ODI identified battery dimensioning as it relates to the battery retention system (hold down bracket, radiator support bolt, J-hook, and battery tray) as the main factor set in the contact between the battery hold down bracket contacting the positive terminal of the 12V battery. The subject vehicles carried over the same battery tray and retention system from the prior generation (MY2006 – MY2012) of RAV4 vehicles. However, the subject vehicles were equipped with a dimensionally smaller battery (Group 35) than the prior generation (Group 24F). The smaller- length measurement in the Group 35 battery size in a battery tray originally designed to fit a Group 24F battery contributed to increased potential for battery movement which was exacerbated by the diversity in aftermarket battery configuration and irregularities intrinsic to battery replacement procedures. Battery movement coupled with the proximity of the B+ terminal on the battery and the grounded electrically conductive hold down bracket set the stage for a short to ground leading to an engine stall (if in operation) followed by a vehicle fire. This investigation was not able to classify the installation status, battery size, or cause of every allegation due to the fire event causing damage to the area, inaccessible vehicle, modification to the battery retention system after the event, and/or inconclusive photographic evidence. Toyota's investigation of the issue identified aftermarket battery catalogs that listed an improper battery replacement size (Group 26R) that would nevertheless fit into the subject vehicles whose battery retention system is incapable of reliably restraining a Group 26R battery. On 18 November 2021, Toyota initiated a consumer advisory campaign (21TG01) to the subject vehicle owners, notifying them of the correct size battery and offering a free inspection of the battery and retention hardware, a caution label to affix to the hold down bracket, and a discounted replacement 12V battery. This investigation with Toyota established three broad categories to characterize the battery retention system state of a given vehicle: "correct", "minor mis-installation", and "major mis-installation". - The "correct" terminology references the front bolt, bracket, and J-hook installed in a position not in contact with the positive battery terminal and the front bolt torqued to 17 Nm and the J-hook engaged with the tray hole and torqued to 4.9 Nm. - A "minor mis-installation" would describe the three retention components installed in the prescribed location, however not to the correct torque values. - The "major mis-installation" condition would constitute a retention component missing or disconnected from the system. Toyota's own testing used five exemplar batteries installed on a subject vehicle in each battery categorization resulted in: - Contact between the B+ terminal and hold down bracket in "major mis-installations" - Movement of the battery in "minor mis-installations" - No observable motion in "correct" installations. ODI conducted its own evaluation of the Toyota- specified replacement battery and 5 aftermarket Group 35 batteries. The six batteries tested conformed to the Group 35 Battery Council International (BCI) standard on overall dimensional tolerance and terminal location. That standard does not define the edge shape or material of battery casing. Physical interaction between the hold down bracket and the battery case and the friction between the casing material and the battery tray resulted in a large variability in movement forces required to incite movement when the battery was installed in the "correct" condition. Resulting in movement at an induced lateral load between 0.6 G and 1.91 G equivalent force across each battery. This force is higher than a typical vehicle could exert in a steady state turn and would only experience loads through brief shock or impulses. Multiple shock or impulse loads across time would contribute to a delay between the replacement battery installation and the fire event. Likelihood of a fire event increases as the installation method degraded from the "correct", to "minor mis-installation", and then to "major mis-installation". Protruding vent caps atop some of the batteries tested aided in restricting battery movement relative to the hold down. An absence of vent caps permitted additional movement. Following several discussions and vehicle inspections with ODI during this investigation, on 01 November 2023, Toyota filed a safety recall (NHTSA 23V-734) of 1,853,568 MY 2013 through MY 2018 Toyota RAV4 vehicles to reduce the risk of a vehicle fire with redesigned battery retention components. To review the ODI reports cited in the Closing Resume ODI Report Identification Number document, go to NHTSA.gov.

The contact owns a 2015 Toyota Rav4. The contact stated that the radio was inoperable. The contact stated that the gauges failed to properly operate. While driving 65 MPH, the vehicle lost power steering functionality. Additionally, the rearview camera image was reversed before becoming inoperable. The ABS, AWD, and engine warning lights were illuminated. The vehicle was taken to an independent mechanic, and an undisclosed fuse was replaced. The mechanic made the contact aware of NHTSA Campaign Number: 15V144000 (Steering). The local dealer was contacted, but the vehicle was not diagnosed or repaired. The manufacturer was contacted and scheduled an appointment with the dealer for the recall repair of NHTSA Campaign Number: 23V734000 (Electrical System). The failure mileage was approximately 189,000.

NHTSA ID

11746428

Incident

Jun 23, 2026

Mileage

189,000 mi

Car’s sunroof exploded while driving, was going about 55 on the highway and I heard a loud pop followed by the sound of breaking glass which I found to be my whole sunroof exploding from the inside out. This is dangerous because of the possibility of glass landing on people or in the car leading to potential injury. This issue is apparently one that happens fairly commonly. The component has not been checked yet. There were no warning signs, just a swift explosion and damage.

NHTSA ID

11740146

Incident

May 26, 2026

Purchased less than 2 months ago from Performance Mitsubishi in Delray Beach FL. Lift gate was not opening and closing properly. Yesterday the hinges broke and lift gate won't shut. It appears there is a class action lawsuit for this issue. I am now responsible for fixing this because the dealership won't.

NHTSA ID

11738886

Incident

May 18, 2026

On Friday February 27, 2026 as the vehicle was being driven it caught fire. Fire department and sheriffs office was called to the scene. Vehicle fire was put out but the whole front end burned.

NHTSA ID

11721498

Incident

Feb 27, 2026

There were two recalls on paint chipping off the body of the car. The last one ended in Nov 2025 I think. BUT...there are many of us who had no idea there was a paint recall, me included. I brought my Rav (great car btw, no issues with how it runs at all) thru a car wash over Thanksgiving, and two softball size paint chips came off, probably due to high pressure water. I then researched the paint and found out that there WAS a recall but I just missed it. This recall needs to be extended needs for I have paint chips missing now all over my car. This is unacceptable from a great car company like Toyota, they need to stand by something so basic as paint quality. The paint color in question is white pearl, code is 070. Thanks for your time here.

NHTSA ID

11710487

Incident

Nov 29, 2025

The oil filter housing is made of plastic and can crack when removing and installing and if not alert after an oil change, the engine can blow if oil drains out under pressure.

NHTSA ID

11709758

Incident

Jan 8, 2026

When we bought the SUV, it had a small top battery installed. The battery slid over and caused my alternator to go out completely. I must have caught fire, as there were burnt wires to the alternator. We replaced the alternator, and it was over $295 dollars and then had to get a new battery, and that was over $150 dollars. I installed it myself because I am a mechanic.

NHTSA ID

11703983

Incident

Oct 12, 2021

The contact owns a 2015 Toyota RAV4. The contact stated that while driving at an undisclosed speed, the vehicle independently accelerated. The contact stated that the failure occurred while the contact was parking the vehicle. The contact's vehicle crashed into a vehicle that was parked beside the contact's vehicle. In addition, the vehicle crashed into the Dollar Tree Store doors. The contact stated that the failure occurred while the brake pedal was depressed and the vehicle was uncontrollable. The contact stated that it was very scary. The Dollar Store door glass was completely shattered. The Dollar Store was closed down as a result of the damage. The vehicle was driven to the contact's residence. The vehicle was not diagnosed or repaired by an independent mechanic or dealer. A Police report was filed. No injuries were sustained. The contact stated that an insurance claim was filed. The contact stated that the failure needed to be investigated by NHTSA. The manufacturer was made aware of the failure, and a case was filed. The failure mileage was approximately 70,450. The VIN was unavailable.

NHTSA ID

11703014

Incident

Dec 3, 2025

Mileage

70,450 mi

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.

21TG01 Exprired - Replaced with Campaign 23TA13 During a recent investigation of reported battery fires in 2013-2018 RAV4 vehicles with gasoline engines (excluding hybrid models), Toyota discovered that many non-Toyota retailers and others who sell or install replacement batteries were recommending a small size battery for replacement. Toyota specifies a particular size replacement battery for the RAV4 that does not include this small size. The smaller battery may not fit securely with the RAV4’s battery mounting parts, and, in some cases, can move around when the vehicle is driven, causing a short circuit. Using the wrong size battery, or not installing a replacement battery properly, can cause damage to the battery and the vehicle, and it could cause a vehicle fire.

Campaign Expired - replaced with campaign 23TA13TECHNICAL INSTRUCTIONS FOR CONSUMER ADVISORY 21TG01 12-VOLT BATTERY SIZE AND INSTALLATION INSPECTION CERTAIN 2013 – 2018 RAV4

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.

Acid rain results from rainwater or other airborne moisture that become acidic due to industrial chemical impurities in the atmosphere. If these acidic compounds settle on an exposed vehicle, especially the horizontal areas such as the hood, roof, and decklid, significant damage to the painted surfaces can occur. Acid rain damage can typically be identified on vehicles by the presence of stains on the paint surface that resemble hard water spots. Unlike water spots however, acid rain damage cannot be removed by regular washing procedures. Also, because acid rain can etch and soften the paint, normal buffing or polishing repair procedures should not be attempted. This can cause further damage and result in visible depressions in the paint surface. The following are the three major categories of acid rain damage: •Minor damage: requires only buffing to repair. •Moderate damage: usually requires neutralizing, color sanding, and buffing. •Severe damage: extending beyond 1/2 mil of clearcoat on a pearl, metallic, or solid color, requires neutralization, sanding, and repainting. In cases where acid rain damage is minor, neutralization and buffing with a liquid-type paint finessing product may provide an adequate repair. Only specially formulated products outlined in this bulletin should be used for that purpose. Unfortunately, other than minor damage, there is no simple method of determining the actual extent (depth) of acid penetration other than color sanding a representative affected area until there is no visible etching or depressions, followed by measuring the amount of paint removed with either a magnetic or digital-type film thickness gauge. The procedures in this bulletin are intended for use by qualified body/paint technicians and should not be attempted by inexperienced personnel. It is the dealer’s responsibility to protect and maintain the quality of the vehicle’s paint finish after receipt at the dealership prior to the first sale. Perform frequent vehicle washing, as often as daily, during high heat and humidity periods to minimize the potential for paint damage due to acid rain exposure. This is especially important in geographical areas known for high frequency and concentration of acid rain and industrial fallout.

To prevent brake rotor rust from forming during transportation and storage, wheel film will be used instead of a cardboard type of anti-rust cover. The purpose of the wheel film is to shield the disc brake rotor from weather elements and initial rust before the vehicle is delivered to the customer. Consequently, the film should remain on the wheel for as long as possible.