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.

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

Lower driver door locking bracket corrosion. Beyond surface corrosion. Been monitoring. Passenger side bracket is free of corrosion. Base of corroded bracket has heavy rust. Appears this part was not plated or treated for rustproofing. Appears this locking bracket might fail over time. See attached photos. Passenger side (no corrosion) is last photo.

NHTSA ID

11750645

Incident

Jul 13, 2026

On 2 seperate occassions I had a wheel on my 2019 Toyota Tacoma come off while driving. Both after Toyota signed off on work orders and bill of sales showing they accessed the wheels. On 4/11/26 the front left drivers side fell off. Upon picking it up after repairs on April 28, May 6th the left rear wheel fell off while driving again. My safety could have been fatal but luckily no injuries for me and a passanger occurred. Toyota used a Certified Toyota body shop to do the repairs on the first incident not sure who worked on the 2nd as I have not yet been notified the truck is ready. The manufacturer has done all the inspecting no other parties have been involved. No warning. Right before each incident the truck would shake then skid along the floor causing sparks.

NHTSA ID

11737733

Incident

Apr 11, 2026

Brake fluid is leaking down the brake pedal and onto the driver's side floormat. Car has less than 60,000 miles and is 7 years old.

NHTSA ID

11737419

Incident

Mar 1, 2026

low pressure fuel pump in fuel tank failed. This part was already repaired from previous recall and failed again. Error code P0087. Vehicle shuttered and stopped in traffic. Broken bits of fuel pump were left in gas tank.

NHTSA ID

11736679

Incident

May 4, 2026

the left side inner and outer tie rods pulled apart at threads at jam nut. The threads approx 2 to three inches of threads were 100% rotted. The jam nut showed no sign of being loose. It did not UNTHREAD. No noise or any indication ever of an issue. It happened at 5:15 am. It was dark. I was at best going 1 mph in reverse. If this had happened at road speeds the outcome could have been fatal for someone. For sure a lot of damage. I did not take a picture my bad. I did ask for the parts back but am 99%sure the part I got was not mine.it had a weld on it likely to move vehicle. The inner tie rod Was cut and looking like new, not a part exposed to the elements for 65k miles. I visually compared to other side. I will dissect it when I go to my friends shop. I could be wrong but doubtful. Call if questions. I had an extended warranty so they covered under that or a warranty/campaign? I was a NIASE AND NOW called ASE certified mechanic specializing in front end repair so…I would not knowingly drive cars that have a safety issue that could kill me or anyone. Safety first.

NHTSA ID

11733180

Incident

Apr 16, 2026

My 2019 Toyota Tacoma (Super White) is experiencing paint chipping and delamination across multiple body panels. Toyota has acknowledged this defect in limited repair programs, but my vehicle is affected beyond the covered areas. Paint loss exposes underlying primer/metal and may lead to corrosion over time. This appears widespread among similar model-year Tacomas.

NHTSA ID

11722840

Incident

Jan 1, 2023

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