2018 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.

Vehicle hits a bump in the road and the check engine light comes on, followed by the gas pedal being non-responsive and an error code on the instrument panel saying “Brake Override System Malfunction. Check with dealer.” and “Pre-collision System Malfunction. Visit your dealer. ” When this occurs, have to coast the vehicle to a safe place, turn off and wiggle the Radar Control piece attached to the front grill sometimes multiple times before the truck will clear the code and accelerate. Been an ongoing issue for several months. Have replaced the front grill sensor and plate and the issue persists.

NHTSA ID

11752269

Incident

Jul 21, 2026

The cab vents failed causing water to soak the carpet and pad from the back wall to the front of the cab. Mold was growing through out the the cab. Carpet & pad had to be removed. This is a known problem by dealerships and owners of Toyota Tacoma. Because the water was under the seats, trim and weather mats it went undetected exposing us to mold. Problem was reported to Toyota dealership and Toyota Corporation. A case was logged 07/10/2026 as Case # 260710001840. The resolution offered was ordering and replacing parts. All parts required for repair and on backorder. Hundreds of orders for these parts in their system. Carpet and under mat had been replaced 05/02/2025 due to a Toyota recall campaign 21TD03.

NHTSA ID

11751422

Incident

Jul 8, 2026

WHAT FAILED: The clear coat finish on the exterior paint of my 2018 Toyota Tacoma has failed (cracking) in two separate locations on the same vehicle, indicating a manufacturing defect rather than normal wear. In late 2024, I discovered clear coat cracking on the roof and hood. I reported this to Toyota (Toyota case #241028000714) and paid approximately $2,000 out of pocket to have an independent body shop repaint the affected panels, as Toyota corporate declined to assist after the repair had already been performed. The clear coat is now cracking again at approximately 48,925 miles, this time on the cab in the pillar/trim area between the tops of the doors and the roofline. The vehicle and affected areas are available for inspection upon request. SAFETY IMPACT: This is a cosmetic exterior paint/clear coat defect. I have not identified any impact on vehicle operation, structural integrity, or visibility, and I am not aware of any safety risk to myself or others resulting from this issue to date. I am reporting it to document a recurring defect pattern on this vehicle. REPRODUCED/CONFIRMED BY A DEALER OR SERVICE CENTER: The 2024 occurrence was inspected and repaired by an independent body shop (not a Toyota dealer). The current occurrence has been reported to Toyota corporate (Toyota Brand Engagement Center) along with photographs, but has not been physically inspected by a Toyota dealer. INSPECTED BY MANUFACTURER, POLICE, OR INSURANCE: Toyota corporate reviewed photographic evidence of the current issue through my correspondence with the Toyota Brand Engagement Center, which I have asked to be linked to prior case #241028000714. Toyota has not physically inspected the vehicle. This is not a crash-related issue, so no police or insurance inspection has occurred. WARNING LAMPS OR PRIOR SYMPTOMS: Not applicable. This is a cosmetic paint/clear coat defect rather than a mechanical or electronic system issue, so there were no dashboard warning lamps or system messages

NHTSA ID

11750035

Incident

Jul 8, 2026

I was traveling southbound on I-25 when the flatbed truck in front of me came to a sudden stop. I was unable to stop in time to avoid rear-ending the truck. The airbags did not deploy upon impact.

NHTSA ID

11749079

Incident

May 1, 2026

The cabin pressure vents, located at the rear of the cab below the rear window on the body frame have failed. The seal on the exterior of the vents has dry rotted. This has caused an extensive amount of water intrusion that is undetectable until it has been present long enough to cause mildew issues. Being that water enters below the vehicle carpet and padding you cannot see it, your first warning sign is smell. When I began to assess the issue I pulled up my carpet to find standing water and mold. This is supposed to be a safe environment where I can transport myself and my family and I now I have to be concerned about mold inhalation each time my toddler sits in my truck. Toyota needs to do an immediate recall to the cabin vents and replace them with a product that can actually with stand the elements. Additionally they need to replace all the carpet, twill, and padding that has been compromised.

NHTSA ID

11747530

Incident

Jun 29, 2026

The contact owns a 2018 Toyota Tacoma. The contact stated that while the vehicle was parked, there was an abnormal odor coming from the inside of the vehicle. While the vehicle was being serviced, the dealer discovered that the inner padding on the front passenger side, the rear passenger side, and the rear driver side was soaked with water, and due to the water accumulation, there was mold forming on the floor. The contact had placed towels to soak up the water while driving; however, the contact later discovered that the mold had spread to the towels as well. No warning lights were illuminated. The dealer diagnosed the vehicle and stated that the rear cabin pressure bin needed to be replaced. The vehicle was not repaired. The manufacturer was notified of the failure. The failure mileage was approximately 144,000.

NHTSA ID

11746680

Incident

Aug 26, 2025

Mileage

144,000 mi

Paint has been peeling from door handles and front bumper

NHTSA ID

11741027

Incident

May 1, 2026

am filing this complaint regarding a power steering rack leak on my [2018] Toyota Tacoma with [83,000] miles, which I purchased used three months ago from Fred Anderson Toyota of Greer in South Carolina. The dealer represented the vehicle as having passed a 160-point inspection and implied CPO-level standards, but it was not actually Certified Pre-Owned. The steering rack is now leaking power steering fluid, with visible accumulation in the boots, despite stable fluid levels in the reservoir during my ownership. This issue appeared very shortly after purchase, raising concerns that it was a pre-existing defect. Power steering leaks can lead to loss of assist and increase crash risk if they worsen. I request that NHTSA investigate whether this represents a safety defect affecting Toyota Tacomas, as similar complaints appear common in owner forums

NHTSA ID

11740010

Incident

May 18, 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