2016 Toyota Tacoma

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.

Toyota has a paint problem on the tacomas. The paint is the bright white, .040 . They have painted all 4 doors,both front fenders and the pillars on each side of the windshield. I’m having the same problem on my hood,top of windshield and bed . Toyota refuses to take responsibility for these areas. They call this a customer satisfaction program instead of a recall so they don’t have to paint the whole truck. I have a 25 year old truck that has better paint than it. I just wanted to let you know about this situation. Thanks [XXX]. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11748666

Incident

Oct 1, 2022

The contact owns a 2024 Ford Edge. The contact stated that the vehicle was shaking while driving. The contact noticed there was fluid emerging from the rear of the vehicle near the tire. There were no warning lights illuminated. The vehicle was taken to the local dealer, who confirmed there was no recall or leak. The vehicle was not repaired. The manufacturer was contacted, who referred to the local dealer. The failure mileage was approximately 100,000.

NHTSA ID

11738757

Incident

May 16, 2026

Mileage

100,000 mi

The original low pressure fuel pump failed at 114,700 miles. The symptoms of the failure were loss of power on the freeway, quickly followed by the engine stumbling, then shutting off completely forcing me to change lanes without power. The vehicles has had to be towed on 2 occasions because of this. The pump was replaced at 114,700 miles by a Toyota dealer at my own cost (no warranty, no recall). Now only 20k miles later the fuel pump has failed again. This issue has put my family at serious risk of accident to complete engine shut off at highway speeds. Now that I am on my third low pressure fuel pump, I have little confidence that this is being addressed by the pump manuf. and Toyota.

NHTSA ID

11736613

Incident

Nov 24, 2023

Dear Toyota Japan Customer Experience Team, I am the owner of a 2016 Toyota Tacoma currently registered in Guam, U.S.A. I am writing to request your assistance regarding a water leak issue from the rear brake light area, which has caused the carpets and seats to become wet and develop mold. I originally purchased this vehicle in Saipan and recently relocated to Guam. When I visited the Guam Toyota Service Center, they kindly inspected my vehicle and informed me that this issue is related to the 3rd brake light gasket recall; however, the recall period has already expired. Unfortunately, I was never notified of this recall while the vehicle was in Saipan. Continuous exposure to mold has seriously affected both my health and my daughter’s health. Because of this, I had the vehicle professionally cleaned and sanitized by a specialist company. The Tacoma has always been our family’s favorite car, but now I drive it only because I have no choice. Every time I get in, I feel anxious and uneasy. The water leak itself is concerning, but the mold issue worries me even more. I truly hope this water leak and the mold problem can both be resolved so that I can once again enjoy driving my Tacoma with peace of mind. The blue circles in the attached photos indicate areas suspected of mold. These photos were taken right before I sent the car for cleaning. According to the cleaning company, when they removed the seats, they found water underneath the seats and carpets. Whenever I drive the vehicle, I experience persistent coughing and headaches due to mold exposure. This has become a serious health and safety concern. Since this issue is directly related to a previously recalled safety defect, I kindly request Toyota Japan to consider a Goodwill Repair or Safety Exception to address the water leak and the resulting interior damage.

NHTSA ID

11730507

Incident

Oct 21, 2025

Severe clear coat and paint fading on hood, roof and sides of truck.

NHTSA ID

11724836

Incident

Jul 10, 2025

2016 Toyota Tacoma is known to have an issue with the timing cover leaking oil. This is a Fire Hazard: Oil leaking onto hot engine components can vaporize and ignite, posing a fire risk to the vehicle and surrounding areas and can cause environmental pollution.

NHTSA ID

11722712

Incident

Jul 5, 2024

The rear passenger door lock actuator on my 2016 Toyota Tacoma failed prematurely, causing the door to no longer lock or unlock properly. The failure required replacement of the entire actuator assembly at a Toyota dealership at a cost of $727.19. This failure occurred without abuse or unusual use and is not consistent with normal wear and tear. I am aware of numerous similar complaints and pending class action lawsuits involving door lock actuator failures across multiple Toyota models, indicating this is a known and recurring defect. A door that cannot reliably lock or unlock presents a safety and security concern, particularly for passengers and children, and increases the risk of unauthorized entry or inability to exit the vehicle in an emergency.

NHTSA ID

11710609

Incident

Jan 5, 2026

2016 Toyota Tacoma – severe clear coat and paint failure on the hood and roof. The clear coat began peeling in 2022 and has progressively worsened. Large sections of the hood and roof show complete delamination, oxidation, and exposed basecoat. This is a widely reported defect for 2015–2017 Tacomas across multiple paint colors. Toyota Customer Care confirmed today that my VIN is not included in Customer Support Program 23TE08 and that no goodwill repair would be authorized, even though the defect is identical to the vehicles Toyota acknowledges as affected. This appears to be a manufacturing defect that compromises durability and corrosion resistance. Photos and documentation are available upon request.

NHTSA ID

11702846

Incident

Jan 1, 2022

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.

Toyota has received some reports of paint peeling along the exterior door window frames, front inner fenders as can been seen with the hood open, and on the A-pillars on certain Tacoma vehicles with 040 Super White paint color. Although the vehicle paint is covered by Toyota’s New Vehicle Limited Warranty for three years, or 36,000 miles (whichever comes first), we at Toyota care about the customers’ ownership experience. Toyota is providing coverage for repairs related to the conditions described above.

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.

TECHNICAL INSTRUCTIONS FOR CUSTOMER SUPPORT PROGRAM 23TE08 COVERAGE FOR PAINT PEELING ON EXTERIOR DOOR FRAMES, FRONT INNER FENDERS AND A-PILLARS CERTAIN 2016-2022 MODEL YEAR TACOMA

Toyota has received some reports of paint peeling along the exterior door window frames, front inner fenders as can been seen with the hood open, and on the A-pillars on certain Tacoma vehicles with 040 Super White paint color. Although the vehicle paint is covered by Toyota’s New Vehicle Limited Warranty for three years, or 36,000 miles (whichever comes first), we at Toyota care about the customers’ ownership experience. Toyota is providing coverage for repairs related to the conditions described above.

Customer Support Program 23TE08 Paint Repair Process Job Aid