2016 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.

Mechanic said he thought rear lower rearward; non-adjustable control arms, lateral arms were a recall. They were falling apart. I've been complaining about a clunky noise for a year or so. Thank you for your help [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11766768

Incident

Sep 24, 2026

I was driving 9/3 and my left blinker light came on solid. I was not using my blinker. Within a few seconds my check engine light came on and another light. Then within 2 minutes the front left engine/tire caught fire.

NHTSA ID

11761822

Incident

Sep 3, 2026

​"The red master warning triangle and an 'SRS Airbag System Malfunction' message illuminated unexpectedly on the dashboard of my 2016 Toyota Rav4 XLE under normal driving conditions. I contacted a certified Toyota dealership, and they confirmed that this dashboard warning indicates the vehicle's airbag system is completely disabled, leaving the occupants without airbag protection in the event of a collision. However, the dealership stated they will not cover the cost to diagnose or repair the system because there is not yet an active safety recall for this specific VIN. I am filing this complaint to formally report this critical safety defect. A premature failure of the vehicle's primary safety restraint system is an immediate and severe safety hazard that warrants a formal NHTSA investigation and a mandatory recall."

NHTSA ID

11760710

Incident

Mar 15, 2026

The repair shop I was able to pull into as I was experiencing the issue with my vehicle reported: "Battery is unstable and is arcing off of the positive terminal. Battery tray, battery hold down tie, and battery j hook hold down were missing upon arrival." The issue was fixed by a Brakes Plus location, given I was able to pull in there - it was around the corner from where I was driving. The issue has been fixed, and I have no issue with inspection of the vehilce. The car died while I was driving on a main street. The recall note states that the vehicle could have caught on fire, though no fire or crash happened. I made a simple right-hand turn and almost every light imaginable illuminated on the dashbard. I was able to turn the vehicle off and on again and get the car to the Brakes Plus location. This location had to order the parts from Kansas. I called the Toyota Dealership informing them what had happened, that the car was unable to be moved and got the response that I needed to take it to them for repair. I called at least two times since I received the notice for the fix in the mail and I was told that I would be contacted when they were ready to fix my car specifically. I was informed they would call, but they did not take down my contact information. I reached out to Toyota and they opened a claim where I uploaded documents - the original recall notice, the letter informing of the fix, the invoice from Brakes Plus, proof of purchase On Friday,XXX, I received a letter notifying me that my claim was not eligible for reimbursement. Since I tried to reach out and get an appointment scheduled inspection and the fix (if needed), and I never received a call to schedule after being told the dealership would reach out to me when they were ready, I believe they should have paid me back for the repair. I can provide the Toyota Brand Engagement Case number as requested. I am hesitant to upload documents here as these documents contain name, address, etc.

NHTSA ID

11757059

Incident

Jul 23, 2026

Intermittent stalling in various conditions including idling, highway driving and city driving.

NHTSA ID

11750762

Incident

Jun 15, 2026

I am filing a complaint regarding Toyota sending out letters to RAV4 owners reference factory paint peeling. The letter stated, “Customer Support Program Notification Paint Peeling (Vehicles Painted with factory-applied blizzard pearl or super white paint). In this letter it stated that it is a possibility veh’s painted with this paint may experience paint peeling off. In the letter it states that if you are not experiencing this issue, there is nothing you need to do at this time. I did not experience any issues at the time. The letter was sent approximately 6-7 years ago. On May 20th 2026 I noticed on the roof of my vehicle between the windshield and sun roof a large softball size area of metal where the paint peeled/flaked off. In contacting Toyota dealership they said there is nothing they can do. Contact was made today 6/15/26 ( I didn’t notice the paint peeling off until 6/13/26). I then called Toyota Corporate and they said since the extended warranty expired 12/11/2025 I have to pay for the fix and they will not. Online there are thousands of others experiencing the same issue. I received a quote of $1600 and $2300 dollars just to strip and repaint the roof. I have the video showing the paint peeling off by itself. This is ridiculous and Toyota needs to be held accountable. According to Toyota the cause of this issue is due to sunlight over time degrades the adhesion between the factory-applied paint primer coat layer and the base metal electrodeposition layer causing the paint to peel from the metal body panel.

NHTSA ID

11744319

Incident

May 20, 2026

Vehicle: 2016 Toyota RAV4 Color: Factory Super White / Blizzard Pearl (whichever applies) I am filing a complaint regarding a well-known latent manufacturing defect involving peeling factory paint on my 2016 Toyota RAV4. The original factory-applied white paint is peeling and delaminating from the exterior metal body panels under normal use and maintenance conditions. The paint failure appears unrelated to any accident, impact, misuse, neglect, or environmental damage. The failed component is the factory-applied exterior paint and coating system on the vehicle’s metal body panels. The affected areas are available for inspection upon request. The paint is separating from the primer/base layer and peeling off in sheets, exposing underlying surfaces and creating risk of corrosion and reduced vehicle value. Toyota has publicly acknowledged widespread issues involving “Super White (040)” and “Blizzard Pearl (070)” paint on numerous Toyota models, including RAV4 vehicles, through Customer Support Program ZKG and multiple Technical Service Bulletins. Toyota documents specifically state the issue involves paint adhesion failure during the manufacturing process causing peeling on exterior metal body panels. This issue creates safety concerns because exposed metal surfaces may eventually corrode or rust, reducing long-term structural integrity and potentially creating visibility distractions while driving as paint continues to separate and peel unexpectedly. Large peeling sections can also detach while driving and create roadway debris hazards for other motorists. The condition has been widely reported by consumers across online forums, complaint databases, and dealerships for many years. Numerous owners of white Toyota vehicles have reported identical failures involving factory paint peeling and delamination. The problem has been visually confirmed by dealership personnel / independent body shop personnel (modify if applicable). And they have refused to cover it at all

NHTSA ID

11739542

Incident

Apr 3, 2026

Air bags malfunction. There is a warning ⚠️ pop up message on my dashboard that says, Air bags malfunction contact manufacturer dealer. This is clearly a safety issue and it should be part of a recall or a recall needs to be started with this issue.

NHTSA ID

11708783

Incident

Mar 3, 2025

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.