2015 Toyota Sequoia

The Office of Defects Investigation (ODI) opened this investigation to determine if the failure of airbags to deploy during severe crashes, in certain vehicles, was the result of a safety related defect.  During the investigation a complex failure was studied that can result in non-deployment of subject vehicle air bags and other restraint system devices in severe crash events. The subject vehicles may be equipped with an airbag control unit (ACU) for the supplemental restraint system (SRS) Electronic Control Unit (ECU) manufactured by ZF-TRW.  The ECU receives signals from crash sensors mounted in the vehicle and deploys the vehicle air bags and seat belt pretensioners in accordance with manufacturer design specifications.  The ECU in the subject vehicles contains a model DS84 application-specific integrated circuit (ASIC) which controls the communication of the crash sensor signal, firing commands (i.e., when to deploy the airbag(s) and/or pretensioners), and fault information (e.g., diagnostic trouble codes). In September 2016, FCA announced recall 16V-668 for certain model year (MY) 2010 to 2014 Chrysler, Dodge and Jeep products manufactured with the subject ZF-TRW ACU.  In this recall, FCA discussed an EOS condition that resulted in a failure of the subject DS84 ASIC, which caused air bag non-deployment.  FCA noted that the defect condition had only been observed in vehicles equipped with sensor harnessing routed across the front of the vehicle.  Other FCA vehicles that also used the subject ACU, but were not equipped with cross-car harnessing, had not experienced EOS failures, despite similar time in service. During the course of this investigation, ODI sent two separate Information Request (IR) letters to six vehicle manufactures (including FCA, Hyundai, Honda, Kia, Mitsubishi, and Toyota) and one IR letter to ZF-TRW.  These IR letters resulted in ODI receiving comprehensive data from these manufacturers and suppliers. Studies of this data found that the DS84 ASIC does not have sufficient protection against negative electrical transients or electrical overstress (“EOS”) that can be generated in certain severe crashes.  An electrical transient occurs when the electrical power supplied to a circuit changes momentarily over a short duration of time.   In these severe crash cases, the crash sensors and other powered wiring can be damaged and short circuited so as to create a negative electrical transient of sufficient intensity and duration (that are outside the vehicle manufacturer's specification) to damage the ASIC before the restraint device deployment signal is received by the SRS ECU.  This damaged signal can lead to incomplete or nondeployment of the air bags and/or pretensioners.  Airbag non-deployment and/or lack of pretensioner operation can increase the risk or severity of injury in a crash.A total of 8 fatalities and 14 injuries were associated with known EOS events. The common element in all investigated manufacturers vehicles is the SRS ECU containing a DS84 ASIC manufactured by ZF-TRW.  The risk associated with the ASIC is equally shared among all OEMS involved in the investigation.  The actual real-world risk can be mitigated by other factors which were assessed by ODI during this investigation. The first mitigating factor involves protections built into the ACU design which protect the DS84 ASIC from damage.  There are multiple strategies and levels of protection employed by different OEMs that provide effective EOS mitigation.  The two most common strategies at the ACU level are circuit protection diodes on the remote senor signal lines, and current limiting resistors that protect critical components. The second mitigating factor is found at the vehicle level and involves the location and routing of the wires leading from the crash sensors to the SRS ECU.  If the wires are well protected in a crash and are not routed with other power wires carrying large currents, the risk for an EOS event is significantly reduced or eliminated. These design specific factors combine to produce a spectrum of risk for the vehicles equipped with ACUs using the DS84 ASIC.  Given the many of years of field exposure, it is possible to divide the subject population into two groups; vehicles which have experienced EOS events, and vehicles which have not experienced EOS field events. Four of the six OEMs involved in this investigation have experienced EOS field events on at least one of their models equipped with a DS84 ASIC.  All vehicle models (including the Toyota models identified in the Failure Report Summary of the opening resume for this investigation) with field events have been recalled.  In an abundance of caution, ODI kept this investigation open five years to monitor field performance and did not identify any field events on vehicles not included in existing safety recalls. Given the spectrum of risk identified in this investigation and that all vehicles with a demonstrated unreasonable risk have been recalled, ODI is closing this investigation. ODI is closing this investigation with the following manufacturer safety recalls: 16V-668, 18E-043, 18V-137, 18V-363, and 20V-024.  With the recall actions taken by the subject vehicle and equipment manufacturers, this investigation is closed. The closing of this investigation does not constitute a finding by NHTSA that a safety-related defect does not exists on other model or model year vehicles outside of the recall scopes. The agency reserves the right to take further action if warranted by the circumstances.

The vehicle is a 2015 Toyota Sequoia with the 5.7L V8 engine and approximately 192,632 miles. The vehicle developed an abnormal internal engine/timing noise, especially when warm. An authorized Toyota dealer inspected the vehicle and diagnosed an internal engine/timing-related condition involving timing chain tensioners, timing chains, chain guides, camshaft gears, lifters, gaskets/resealing, and related labor. The estimated repair cost is approximately $19,716. The concern is safety-related because if the timing chain, tensioners, or related internal engine components fail while the vehicle is being driven, especially at highway speeds, the engine could stall, lose motive power, or become unable to safely continue operating. A sudden loss of motive power in traffic could increase the risk of a crash and put the occupants and other motorists at risk. This is a family vehicle used to transport young children, so the risk is not theoretical or acceptable. The problem has been confirmed by an authorized Toyota dealer. The vehicle and affected components are available for inspection upon request. The vehicle has been consistently maintained per the manufacture's schedule. Separate wear items were already repaired as needed. The dealer’s diagnosis concerns internal engine/timing components consistent with manufacturer defects, not ordinary maintenance items. To my knowledge, the vehicle has not been inspected by the manufacturer, police, insurance representatives, or any agency other than the Toyota dealer. Warning lamps or messages are UNKNOWN. The primary symptom before repair was abnormal internal engine/timing noise. This complaint is being submitted to document a potentially serious internal engine/timing component condition that could affect the vehicle’s ability to safely propel itself if the failure progresses. Thank you for your time and attention to this matter.

NHTSA ID

11744827

Incident

May 26, 2026

Rear latch not locking or latching correctly leading to liftgate opening while driving. Has happened repeatedly, will latch some days and not other dealer said no recalls available but seems to be common problem on online forums.

NHTSA ID

11633181

Incident

Dec 20, 2024

My wife was driving Interstate 81 from Tennessee to West Virginia at 70 mph when her right front tire blew out. Two months prior to this we were driving approximately 40 mph on a back road and the left front tire blew out. These are Pirelli Scorpion Verde All Season 275/55 R20, purchased approximately in August 2020, with approximately 40,000 miles.

NHTSA ID

11472009

Incident

Jun 18, 2022

WE PARKED OUR CAR IN OUR GARAGE AT ABOUT 11:30 AM. I WENT TO THE GARAGE AROUND 4PM TO GET MY WALLET AND THE SUNROOF WAS SHATTERED. THERE WAS A SMALL AMOUNT OF GLASS IN THE CAR, AND MORE GLASS ON TOP. THE GLASS WAS CRACKED AND BOWED UPWARDS, LIKE IT HAD EXPLODED FROM THE INSIDE. THERE WERE NO CRACKS IN THE GLASS PRIOR TO THIS, NOR WAS THE TEMPERATURE BELOW FREEZING THAT DAY. NOTHING COULD HAVE FALLEN ON THE ROOF IN THE GARAGE. I CAN'T THINK OF ANYTHING THAT WOULD HAVE CAUSED THAT MUCH DAMAGE TO THAT TYPE OF TEMPERED GLASS AND US NOT REALIZE IT. IT'S LIKE IT JUST BLEW UP FROM THE INSIDE, IVE NEVER SEEN ANYTHING LIKE IT.

NHTSA ID

11289557

Incident

Dec 14, 2019

Mileage

100,042 mi

TL* THE CONTACT OWNS A 2015 TOYOTA SEQUOIA. THE CONTACT STATED THAT THE FRONT PASSENGER SEAT BELT INDICATOR FLASHED, WHICH INDICATED THAT THE SEAT BELT WAS NOT ENGAGED. CRYSTAL TOYOTA (220 US-22, GREENBROOK, NJ 08812, (732) 968-1000) DIAGNOSED THAT THE FRONT PASSENGER SEAT OCCUPANT SENSOR NEEDED TO BE REPLACED. THE DEALER STATED THAT THE FRONT PASSENGER SEAT NEEDED TO BE REPLACED BECAUSE THE SENSOR WAS ATTACHED TO THE FRONT PASSENGER SEAT. THE MANUFACTURER WAS CONTACTED. THE APPROXIMATE FAILURE MILEAGE WAS 32,000.

NHTSA ID

11256442

Incident

Jun 1, 2017

Mileage

32,000 mi

WHILE DRIVING STRAIGHT ON A CLEAR AND SUNNY DAY ON A HIGHWAY WITH FEW SURROUNDING VEHICLES, WHAT SEEMED LIKE EXPLOSION WAS FELT AND HEARD. A QUICK ASSESSMENT WAS MADE TO DETERMINE THAT THERE WAS NO ROAD DEBRIS, THE TIRES DID NOT BLOW OUT, AND THERE WAS NO ISSUE WITH ANY SURROUNDING CARS. WHILE THE DRIVER SOUGHT A SAFE PLACE TO PULL OVER, THE PASSENGER LOOKED AROUND THE VEHICLE TO FIND ALL WINDOWS IN TACT AND SLIGHTLY OPENED THE MOON SHADE, TO DISCOVER THAT THE SUNROOF WAS CRACKED. AFTER PULLING OVER, THE SUNROOF WAS INSPECTED FROM THE EXTERIOR AND THE GLASS WAS NOTICEABLY BOWED OUTWARD, SUGGESTING AN EXPLOSION VS. AN ARTICLE HITTING THE GLASS TO CAUSE THE BREAK. NUMEROUS ACCOUNTS OF SUNROOF EXPLOSIONS HAVE BEEN FOUND ONLINE.

NHTSA ID

11083080

Incident

Apr 2, 2018

Mileage

40,300 mi

TOYOTA COMPLAINT, DANGEROUS COMPUTER PROGRAM, CAN CAUSE DEATH. TOYOTA PROGRAMS THE CAR COMPUTER TO POST A "MAINTENANCE REQUIRED" SIGN TO POP UP ON THE DASH. IT HAS A "RED TRIANGLE" ALSO TO GET YOUR ATTENTION. THE SIGN STAYS ON CONSTANTLY UNTIL YOU TAKE YOUR VEHICLE INTO TOYOTA TO BE SERVICED. THIS SIGN IS VERY VERY DISTRACTING WHILE DRIVING BECAUSE YOU CAN NOT SEE YOUR SPEED THAT IS HIDDEN BY THE SIGN WHEN YOU TRY TO SET YOUR CRUISE CONTROL. I HAVE RUN OFF THE ROAD SEVERAL TIMES WHILE TRYING TO ADJUST MY CRUISE CONTROL AND COULD NOT SEE IT BECAUSE OF THE MAINTENANCE SIGN. IT IS A VERY DANGEROUS SIGN AND TOYOTA SHOULD REMOVE IT FROM THE COMPUTER PROGRAM. I HOPE SOMEONE FILES A CLASS ACTION LAW SUIT AGAINST TOYOTA TO FORCE TOYOTA TO REMOVE THE MAINTENANCE REMINDER SIGN FROM THE COMPUTER. [XXX], [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6).'*JB

NHTSA ID

11032556

Incident

Oct 8, 2017

Mileage

130 mi

WIRING HARNESS WAS CHEWED ON BY RODENT. TOYOTA WILL NOT PAY FOR FIXING BRAND NEW VEHICLE. FOUND SEVERAL OTHER COMPLAINTS ONLINE AFTER TOYOTA HAS MOVED TO "PLANT-BASED" MATERIALS FOR WIRING HARNESSES. HAVING ELECTRICAL ISSUES WITH VEHICLE WITH ONLY 11K MILES.

NHTSA ID

10855227

Incident

Apr 4, 2016

Mileage

11,000 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.

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.

The condition known as acid rain is caused by airborne chemicals or particles in the atmosphere, which mix with rainwater, nighttime dew, or high humidity to form acidic compounds. If these contaminants settle and remain on a painted vehicle surface, especially the horizonal areas of the hood, roof, and decklid, significant damage can occur. This damage is the result of actual etching of the paint and appears as pitting or water spots. As acid rain droplets on the vehicle surface evaporate, the concentration strength of the acid increases, causing deeper and more rapid damage. This evaporation and corrosive action also occur more rapidly on dark colored cars as direct sun heat increases. 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. In areas known for high frequency and/or concentration of acid rain, frequent vehicle washing during high heat or humidity periods will minimize the potential for paint damage caused by acid rain. It is further recommended that either reverse osmosis or deionized water be used to prevent water spotting.

Toyota vehicles are currently protected with RapgardTM protective film designed to protect the horizontal painted surfaces. This material protects from acid rain, environmental fallout, and rail contamination. Follow the Removal Procedure in this bulletin to remove the RapgardTM protective film within 90 days from initial application.