2019 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.

I wrecked my truck in a snowstorm, and the front airbags did not deploy. The crash had me and 2 others in my vehicle. I have permanent injuries

NHTSA ID

11762405

Incident

Jan 27, 2021

The brakes failed, out of nowhere, no codes and no warning. The vehicle was taken to lithia Toyota of [XXX] on XXX for inspection and they say they couldn’t recreate the issue. 5 days later the vehicle was taken to Grants Pass Toyota and they have isolated the issue to be a faulty master cylinder. My safety and everyone on the road was at risk because one dealership failed to correctly inspect and diagnose the issue, all documentation is available. The issue was reproduced by Grants pass Toyota in less than 5 minutes of arrival to their service department. The master cylinder for like vehicles were recalled and mine was manufactured within 4 months of those models that fell into the J16/J06 recall. The exact symptoms that my vehicle experienced. However, my vin was not included in that recall. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11762033

Incident

Aug 22, 2026

The contact owns a 2019 Toyota Tacoma. The contact stated that while the vehicle was parked, the vehicle shuddered, stalled, and there was an abnormal sound coming from the vehicle. The contact turned off and restarted the vehicle, and the vehicle returned to normal operation. The failure occurred on several occasions. The check engine and the active traction control warning lights were illuminated, with several other unknown warning lights illuminated. The vehicle was taken to a dealer to be diagnosed; however, the dealer stated that the cause of the failure was unknown. The vehicle was not repaired. The vehicle was taken back to the residence, and the contact used a diagnostic tool to retrieve DTC: P0087 (Fuel Rail/System Pressure was too Low). The vehicle was not repaired. The vehicle was taken back to the dealer, where it was determined that the octane fuel or spark plugs might need to be replaced. The vehicle was not repaired. The contact researched and was made aware of an unknown recall; however, the VIN was not under recall. The manufacturer was not notified of the failure. The failure mileage was approximately 40,000.

NHTSA ID

11761065

Incident

Dec 31, 2022

Mileage

40,000 mi

My car had a lamp seal replaced (00948-CHMSL Center High-Mounted Stop Lamp Seal) in 01/2020. When it rains, water is getting into my car. I can't determine if the same seal or a new seal is failing to keep the water out. This is creating a higher probability of generating a mold issue in my car.

NHTSA ID

11760297

Incident

May 9, 2026

Brake Master cylinder. The brakes lose all pressure and do not stop the truck all of a sudden. This is an open recall on many of these trucks but apparently my specific truck isn’t included in this. Because it just happened we are looking for the parts to fix this. Although it’s to the tune of over $1,000. There are no warnings, no lights nothing. Just went to pull out of my driveway and have no brakes. Although the pads are brand new and professionally installed.

NHTSA ID

11758799

Incident

Aug 21, 2026

The contact owns a 2019 Toyota Tacoma. The contact stated that while driving at an undisclosed speed, there was an abnormal sound coming from the A/C, and the cool air setting was inoperative. No warning lights were illuminated. A vehicle was taken to a dealer to be diagnosed; however, the vehicle was not diagnosed or repaired. The dealer stated that there was UV dye at the evaporator core and that refrigerant was leaking. The vehicle was taken back to the residence. The manufacturer was notified of the failure. The failure mileage was approximately 76,000.

NHTSA ID

11757765

Incident

Jul 19, 2026

Mileage

76,000 mi

Brake master cylinder failed on 2019 Toyota Tacoma. Vehicle had ~40000 miles at time of failure summer of 2025. Out of pocket expense was over $2000.00.

NHTSA ID

11756579

Incident

Aug 1, 2025

Brake pedal started sinking to the floor. Inspected and no fluid leaks present. If brake pedal is pumped, it will build pressure. Then the check brake system light comes on. That is a sign of brake master cylinder failure.

NHTSA ID

11753935

Incident

Jul 30, 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