2017 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.

LOWER FUEL PUMP FAILS AT HIGH SPEED OR IN COLD WEATHER I WAS TOLD BY TOYOTA SERVICE.

NHTSA ID

11405346

Incident

Mar 9, 2021

Mileage

31,000 mi

CAR SHOOK AT 50 MILES PER HOUR AND ABOVE, CHECK ENGINE AND 4 LO LIGHTS FLASHED. TOOK TO MECHANIC AND WAS TOLD FUEL PUMP NEEDS REPLACING. TOYOTA ADVISED THAT MY VIN WAS NOT PART OF THEIR CURRENT RECALL.

NHTSA ID

11404355

Incident

Mar 21, 2021

Mileage

55,000 mi

SPONTANEOUSLY SHATTERING SUNROOF. THE SUNROOF SPONTANEOUSLY SHATTERED WHILE I WAS DRIVING.

NHTSA ID

11375684

Incident

Nov 20, 2020

Mileage

32,900 mi

WHEN TRAVELING ON THE FREEWAY AT 65-70MPH THERE IS A WHISTLING OR METAL TO METAL SOUND THAT HAPPENS ON THE LEFT SIDE OF THE CAR. I CAN'T TELL IF IT'S IN THE WINDSHIELD OR THE FRAME AREA. ALSO THERE IS A CONSTANT SQUEAK ON THE RIGHT CORNER OF THE WINDSHIELD AT THE DASHBOARD

NHTSA ID

11316285

Incident

Nov 22, 2019

Mileage

17,450 mi

TL* THE CONTACT OWNS A 2017 TOYOTA SEQUOIA. THE CONTACT STATED THAT WHEN THE VEHICLE WAS POWERED OFF, THE ENGINE CONTINUED TO RUN. THERE WAS NO WARNING INDICATOR ILLUMINATED. THE VEHICLE WAS TAKEN TO PALMER'S TOYOTA SUPERSTORE (LOCATED AT 470 SCHILLINGER RD, MOBILE, AL 36695, (251) 639-0800) WHERE THE CONTACT WAS INFORMED THAT A LOW BATTERY WAS CAUSING THE FAILURE. THE CONTACT INFORMED THE DEALER THAT HE HAD JUST CHARGED THE BATTERY BEFORE BRINGING IT TO THE DEALER BECAUSE THE FAILURE CAUSED IT TO DRAIN. THE VEHICLE WAS NOT REPAIRED AND THE FAILURE RECURRED. THE VEHICLE WAS NOT TAKEN BACK TO THE DEALER. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 52,000.

NHTSA ID

11205971

Incident

Apr 30, 2019

Mileage

52,000 mi

ON JULY 12, 2017, I HAD BACKED UP MY 2017 TOYOTA SEQUOIA TO A FAMILY MEMBER'S HOUSE AND THEN PUT THE VEHICLE IN PARK, BUT LEFT IT RUNNING. MY THREE CHILDREN REMAINED INSIDE THE VEHICLE, SEATED AND BUCKLED. I EXITED THE VEHICLE TO WALK TO THE BACK AND PUT A BOX IN THE BACK AND WHEN I TURNED AROUND, THE VEHICLE HAD SUDDENLY ACCELERATED AND WAS SPEEDING AWAY. THE VEHICLE STRUCK A SMALL SECTION OF TREES ON THE RIGHT SIDE, WHICH POPPED THE FRONT PASSENGER DOOR OPEN. THE VEHICLE THEN CONTINUED ON UNTIL IT RAN THROUGH TWO FENCES AND INTO THE WOODS BEHIND THE NEIGHBOR'S HOUSE, WHERE IT STRUCK OTHER TREES AND CAME TO A STOP. UPON CATCHING UP WITH THE VEHICLE, THE ENGINE SOUNDED AS THOUGH IT WAS STILL REVVING AND WAS DIGGING RUTS INTO THE GROUND. I OPENED THE DRIVER'S DOOR AND FOUND THE GEAR SHIFT JUST SLIGHTLY OUT OF PARK, WHICH IS NOT WHERE I LEFT IT. I HAD TO FORCEFULLY PUT IT BACK INTO PARK BY HITTING IT AND THEN TURNED THE KEY OFF. THE MOTOR WOUND DOWN WITH A HIGH PITCHED WHINING NOISE. I THEN UNBUCKLED ALL THREE OF MY CHILDREN (AGES 11, 9, AND 5) AND GOT THEM OUT OF THE VEHICLE. THE VEHICLE WAS HEAVILY DAMAGED IN THE FRONT END AND PASSENGER SIDE BUT NO AIRBAGS DEPLOYED. THERE HAD BEEN TWO OTHER INSTANCES OF TROUBLE WITH THIS VEHICLE PREVIOUSLY THAT TOYOTA HAD STATED THEY COULDN'T FIGURE OUT WHAT THE PROBLEM WAS. THE FIRST WAS APPROX 2 WEEKS AFTER PURCHASE WHERE IT WOULD LOSE POWER WHILE DRIVING AND THEN SUDDENLY GET IT BACK AND SURGE. THE SECOND OCCURRED IN MARCH 2018 AND THE VEHICLE WOULD SUDDENLY DECELERATE WHILE ON CRUISE CONTROL, EVEN WHEN THERE WERE NO VEHICLES IN FRONT, AND THEN SUDDENLY REACCELERATE. NEITHER TIME TOYOTA COULD PINPOINT A CAUSE OR FIX FOR EITHER BUT THE VEHICLE SUDDENLY WORKED AFTER THEY CHECKED IT OUT. THE EDR REPORT COLLECTED BY TOYOTA CONTAINED A LARGE AMOUNT OF INCORRECT DATA, SUCH AS THE VEHICLE ROLLING OVER WHEN IT DID NOT AND OTHER INFO.

NHTSA ID

11152216

Incident

Jul 12, 2018

Mileage

30,500 mi

TL* THE CONTACT OWNS A 2017 TOYOTA SEQUOIA. WHILE DEPRESSING THE ACCELERATOR PEDAL, THE VEHICLE FAILED TO ACCELERATE. THE VEHICLE WAS TAKEN TO PRIORITY TOYOTA CHESAPEAKE (1800 GREENBRIER PKWY, CHESAPEAKE, VA 23320) WHERE IT WAS DIAGNOSED THAT RODENTS CHEWED HOLES THROUGH THE WIRING THAT WAS LUBRICATED WITH PEANUT OIL. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE VIN WAS UNKNOWN. THE APPROXIMATE FAILURE MILEAGE WAS 6,200.

NHTSA ID

11073761

Incident

Jan 31, 2018

Mileage

6,200 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.

Some customers may experience echoing on the line calling the vehicle when using Bluetooth Hands Free. This is caused by the phone Hands Free volume being too low.

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.