2017 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 sunroof/moonroof glass on my 2017 Toyota RAV4 XLE suddenly shattered while I was driving on the highway. I heard a very loud explosion-like sound, and the sunroof glass broke unexpectedly. I did not observe any object, rock, or road debris striking the sunroof before it shattered. The remaining damaged sunroof and vehicle are currently available for inspection upon request. This incident put my safety and the safety of others at risk because the sunroof shattered unexpectedly while I was traveling on the highway. The sudden loud sound startled me while I was driving, and broken glass was left across the sunroof area and continued to break and fall from the damaged glass. I was concerned that additional pieces could come loose while the vehicle was being driven. The problem has not yet been reproduced or confirmed by a Toyota dealership or independent repair facility. The sunroof has not yet been professionally repaired. At this time, the vehicle and sunroof have not been inspected by Toyota or a Toyota dealership regarding the cause of the failure. I have photographs and/or video documenting the condition of the sunroof after the incident. There were no warning lights, dashboard messages, or other warning symptoms before the sunroof shattered. The failure happened suddenly and without warning while I was driving on the highway.

NHTSA ID

11755676

Incident

Aug 6, 2026

This vehicle has twice had the same issue where the sunroof drain lines become clogged or dislocated and the water fills the liner in the front driver and passenger seats resulting in flooding in the compartment and mold damage throughout the interior. the mole spore are transmitted throughout the interior. The water damaged the airbags and the electrical harness in the dash of the car resulting in the dashboard electrical system shutting off and restarting spontaneously while driving. The leaks were repairs and the interior replaces in october 2023 and the same incident has recurred in august 2026. The claims adjuster recommends that the entire wiring harness, airbags, and carpets, seats and liners be replaced for health and safety of passengers.

NHTSA ID

11755337

Incident

Aug 1, 2026

Odometer Fraud. The contact purchased a 2017 Toyota Rav4. It was discovered that there was a mileage discrepancy. The vehicle was a private sale. At the time of purchase, the vehicle mileage was 110,000 and at the time of a Carfax check, it was discovered that the mileage was 300,000.

NHTSA ID

11754062

Incident

Jul 15, 2026

Mileage

300,000 mi

The liftgate on my 2017 Toyota RAV4 has been having issues for a couple of months. Makes a horrific noise when opening and closing. On several occasions it won't even open but about 5 inches then stops. The driver's side door won't lock/unlock with the smart key fob. I have to manually lock it and then use the "key" in the fob to unlock it. It is very hard to turn the key and I am always afraid it is going to break off in the lock. I feel this is dangerous for me that the time it takes to do this, something could happen to me. I have checked a couple of places for repair of the lock and it can run between $600 and $800 per lock.

NHTSA ID

11745217

Incident

Apr 6, 2026

Rust on roof by the windshield

NHTSA ID

11730426

Incident

Apr 6, 2026

Yesterday March 25th 2026 I went to work and parked my 2017 Toyota RAV4 and about 30minutes later it was on fire in the parking lot. The fire happened around the battery area

NHTSA ID

11727377

Incident

Mar 25, 2026

PCS brake has enormously engaged twice. 1. small branch fell off tree on a dirt road. brakes engaged and should not have and almost caused vehicle to slide off a 1000 foot cliff. 2. auto braked with my dog was in car and broke dogs' leg and cost a 2,000 dollar vet bill. brakes where not needed i could have easily just did a slight steering adjustment to avoid collusion. the braking prevented that and almost was also almost rearended overall, the autobrake can be disabled with a lot of work on various menus. but comes on when the car is restarted. I do this every time i restart the car. I suspect a glitch or a low voltage caused it to come back on. Also trying to always remember to do it is difficult to do. I consider this auto brake to be a huge safety risk and could cause loss of life. I am so scared by this and afraid to dive the car now. may have to take a total loss on the car I just bought. Toyota dealers said they cannot reprogram the car to prevent this serious safety risk

NHTSA ID

11717895

Incident

Feb 12, 2026

While my child was sitting in his carseat, the foam head support detached from the plastic casing where it is glued together. This is not the result of any action on our part and the seat has not been in car accident. The glue just gave out.

NHTSA ID

11715647

Incident

Feb 3, 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.

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.