2018 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.

Before o had taken my RAV4 into Toyota for the recall a AAA tech. had replaced the battery after jump starting it. There was nothing wrong with the sensors or anything else but after the battery was replaced all the electric sensors that are for lane change warnings and cruise control etc. stopped working. I took vehicle into Toyota of Santa Maria and was told that I needed to pay for the sensors that had failed. They told me that I was responsible and I do not believe I am when AAA had just replaced my battery and only after that did the sensors have an issue. I do not feel safe driving my car now because all the sensors aren’t working anymore.

NHTSA ID

11754574

Incident

Jun 20, 2026

The contact owns a 2018 Toyota Rav4. The contact stated that while in reverse(R), the rear-view camera was black and failed to operate as intended. The vehicle was taken to a dealer where it was diagnosed and determined that the camera was inoperable and needed to be replaced. The vehicle was not repaired. The manufacturer was notified of the failure and a complaint was filed. The failure mileage was approximately 40,000.

NHTSA ID

11753295

Incident

Mar 15, 2026

Mileage

40,000 mi

The hands free feature over the cars microphone/stereo is unusable; leaving vehicle owners frustrated, and more likely to operate cellphones outside of standard hands free practices. I have been on numerous phone calls where people have told me that they were unable to hardly hear a thing I was saying. To remedy this problem I have 1. Tried speaking up (even yelling) 2. Turning off HVAC systems 3. Positioning my body closer to the microphone 4. Bringing the car to a slow or stop to reduce road noise. 5. Calling myself to see if I can hear myself. 6. Talked with someone who owns the same car (year/model/spec/trim) and they were hardly audible as they called me over their hands free system.

NHTSA ID

11749459

Incident

Jul 10, 2026

While I am driving my Toyota RAV4, the car will suddenly shut off and I can restart it and keep driving as the month is going on. The incidents are happening more often and now the dashboard is going black. I’ve had a couple of warning signs on the dashboard. I brought the car to Toyota and Pep Boys. Both of them checked the electrical systems and everything looks good according to their testing.

NHTSA ID

11748370

Incident

Jun 19, 2026

My lift tailgate is malfunctioning. Continued forced opening can cause the hinges to crack and messes with the alignment and closing of the tail gate making it a safety issue.

NHTSA ID

11746910

Incident

Jun 12, 2025

We were part of a 4 car collision on the freeway. A Ford Expedition that was slammed into then slammed into our RAV. The airbags never deployed and an error code came up saying fail for airbags.

NHTSA ID

11745520

Incident

Jun 21, 2026

Severe, chronic rainwater intrusion through the vehicle's front cowl and body seams, resulting in catastrophic flooding of the passenger-side cabin floorboards. This issue occurs even when all sunroof drains are completely clear and functional. Toyota has issued Technical Service Bulletin 0055-24 acknowledging body seam and cowl leaks for this vehicle type. The passenger-side floorboard houses critical electrical wire harnesses and sits adjacent to the Supplemental Restraint System (SRS/Airbag) control module. Chronic standing water on the floorboard presents an immediate risk of electrical short-circuits, potentially causing sudden vehicle stalling, electrical component fires, or the uncommanded deployment/failure of the vehicle's airbag safety systems. Furthermore, the thick foam insulation beneath the carpet remains saturated, creating an immediate, toxic mold hazard within an enclosed passenger cabin, severely impacting occupant health and air quality. The manufacturer and dealership have left the vehicle unrepaired for over 30 days, refusing to remediate this safety hazard.

NHTSA ID

11740651

Incident

May 1, 2026

The contact owned a 2018 Toyota RAV4. The contact stated that the vehicle experienced a defect with the key fob and the door locks for the passenger doors. When starting the vehicle, the brake locking mechanism could not detect the key, and a message was displayed indicating that the key was not found. The contact stated that he had to open and close the door for the vehicle to engage and recognize the key. Additionally, the vehicle failed to lock automatically, which forced the contact to lock both the driver and passenger sides manually. Early corrections were made in an attempt to resolve these issues, but the problems persisted. The dealer was notified of the failure. The vehicle was not repaired. The manufacturer was notified of the failure. The failure mileage was 54,968.

NHTSA ID

11740582

Incident

May 1, 2025

Mileage

54,968 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.