2017 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.

The authorized factory campaign repair for the third brake light leak (21TD03) was performed in 2021 but failed due to deficient dealership workmanship. Water intrusion continues to flood the rear interior cab, resulting in severe mold growth throughout the interior. This is a severe health and safety biohazard making the vehicle unsafe to operate. The manufacturer and dealer refuse to communicate or remedy the failed safety repair.

NHTSA ID

11775655

Incident

Sep 15, 2021

The contact owns a 2017 Toyota Tacoma. The contact stated that while driving in the rain, the passenger inside the vehicle became aware of fluid leaking inside the cabin of the vehicle from the third rear brake light. The contact inspected the vehicle and became aware that there was mildew nearby where the failure started. There was an odor inside the vehicle and thought that the failure was coming from the cabin air filter. The contact stated that the instrument panel lights and the display screen were not illuminating properly at night. The manufacturer was notified of the failure. The vehicle was taken to the dealer where it was diagnosed with a failure of the seal on the third brake light. The failure mileage was 55,000.

NHTSA ID

11774055

Incident

Jun 15, 2026

Mileage

55,000 mi

Rear pressure vents leak and can cause mold with can cause breathing problems.

NHTSA ID

11771837

Incident

Oct 1, 2026

Description of the Problem: I am filing this safety complaint regarding severe, premature clear coat failure on my 2017 Toyota Tacoma (Magnetic Gray Metallic). The factory paint defect is actively creating two distinct safety hazards involving driver visibility and cabin air quality. First, the clear coat on the hood has failed in uneven, patchy areas, exposing the base coat. The stark contrast between the dull exposed paint and the remaining clear coat creates highly irregular, fractured sun glare. When driving in direct sunlight, this uneven reflection casts unpredictable, blinding glare directly into my line of sight through the windshield, temporarily compromising forward visibility. Second, the clear coat is actively chalking and degrading into a fine chemical dust. Because this deterioration is occurring heavily on the hood, aerodynamic airflow during normal driving sweeps this micro-particulate dust directly into the cowl intake vent located at the base of the windshield. As a result, the HVAC system pulls these deteriorating clear coat particles into the passenger cabin. This introduces airborne chemical dust into the enclosed vehicle, creating a continuous inhalation and respiratory hazard for the driver and passengers. Toyota is aware of widespread paint adhesion and clear coat issues. They have issued Customer Support Program (CSP) ZKG to repair peeling paint on specific white colors (040/070), but they are refusing to acknowledge the exact same chemical failure occurring on their Magnetic Gray Metallic vehicles. Dealerships and the Brand Engagement Center routinely dismiss these failures as "environmental damage." This is a structural failure of the exterior coating that actively impairs safe vehicle operation due to visibility hazards and the ingestion of chemical particulates into the cabin air supply. I am urging the NHTSA to investigate this widespread defect on Magnetic Gray Metallic Toyota vehicles.

NHTSA ID

11770702

Incident

Oct 16, 2024

Vehicle: 2017 Toyota Tacoma Issue: Persistent water intrusion, extensive mold contamination, and unresolved condition following Toyota Limited Service Campaign 21TD03. Approximately 12–18 months ago, Gray-Daniels Toyota in Brandon, Mississippi, performed Toyota's service campaign addressing water intrusion through the rear center high-mounted brake light. At that time, the vehicle's carpeting was wet and mold-contaminated. The dealership replaced all carpeting as part of the campaign repair. Within two days of receiving the vehicle, I contacted the dealership's service department and reported that the interior remained wet and the condensation problem had not improved. The service department advised me by telephone that Toyota was aware of another water-intrusion problem involving the rear cabin vents. I was informed that nothing further could be done unless I paid for an expensive additional repair. The dealership did not reinspect the vehicle. The water intrusion continued, and the vehicle now has extensive visible mold contamination, particularly in the rear floor area. I no longer consider the vehicle safe to occupy or operate because of concerns about exposure to mold and airborne contaminants. I am concerned that the original manufacturer-authorized repair failed to resolve the water intrusion, that an additional known source of water intrusion was not investigated, and that the resulting contamination presents a potential occupant health and safety hazard. I request that NHTSA review this condition to determine whether the water-intrusion defects and resulting contamination warrant further safety investigation, including whether other Toyota Tacoma owners have experienced similar problems following completion of the service campaign.

NHTSA ID

11770249

Incident

Oct 9, 2026

While driving at highway speeds on the interstate, the driver-side sun visor suddenly experienced an internal mechanical failure, snapping at the pivot point. Instead of detaching completely, the visor dropped down into a vertical position, completely blocking my forward windshield view. Because this occurred while driving directly into blinding sunlight, the combination of the obstructed windshield and the sudden, unshielded sun glare caused an immediate and severe loss of forward visibility. This created an imminent crash hazard on a high-speed roadway, requiring an emergency reaction to blindly clear the obstruction from my field of vision while attempting to maintain vehicle control.

NHTSA ID

11769937

Incident

Oct 8, 2026

My 2017 Tacoma TRD Off Road (manual transmission) makes a constant chirping sound when the engine is running and increases chirping sound when accelerator is pressed. The chirping sound ceases when the clutch is pressed in. It's clear through research that this is a "throw out bearing" issue. Toyota dealership confirmed the same issue and replaced the throw out bearing on 6/24/26 through 7/2/26 (as covered by extended warranty). On 7/3/26, the chirping sound remains, possibly worse/louder. On 8/28/26 through 8/31/26, a different Toyota dealer changed the throw out bearing again, but added changing the entire clutch system (being clutch disc assembly, clutch cover assembly, pressure plate, fly wheel and fly wheel sub assembly). Car was picked up and still makes chirping noise. Research of this issue notes: Quill Wear: The aluminum snout (quill) the bearing slides on can groove and wear down over time; and Toyota TSB: Dealerships previously addressed this under technical service bulletins with updated OEM replacement parts, though the noise can sometimes return if the core design interaction isn't changed. This is a design flaw, using an aluminum snout/quill versus a steel snout. This issue is all over the internet, although when I called Toyota Brands, they said they cannot help me. This should be a recall item for Toyota to fix.

NHTSA ID

11761605

Incident

May 13, 2026

The parking brake sticks. This is an issue because the vehicle automatically applies the parking brake briefly when switching from neutral to first gear or reverse to prevent rollback. When this happens, the parking brake sticks, and the rear wheels lock. I believe the brake cables have been infiltrated with water resulting in rust/corrosion.

NHTSA ID

11758934

Incident

Aug 20, 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.

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