2016 Toyota Tundra

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.

2016 flex fuel toyota tundra with 118,00 miles was towed to toyota dealer in Las cruces with a no fuel issue. After the analysis it was determined the fuel pump over heated burning out conector and wiring ,but the pump was still working. According to toyota TSB 0166-19 this is a problem the can arise if the alcohol fuel density ID is not updated. I told the dealer to due repairs on vehicle even though a fuel pump was installed and reflashed at 114,000 miles. Viva toyota of las cruses advicate stated that a reflash is all the vehiles needs and does not desire to change the alchol fuel density to updated ID as per TSB-0166-19, so I am worried I will be operating a vehicle with a fuel pump that will over heat and burn out connectors again. I called Toyota complaints and they told me they cannot make a dealer do any repairs.

NHTSA ID

11752420

Incident

Jul 2, 2026

Bed is rusting out from the bottom in a fashion that looks very similar to a previous Tundra bed rusting issue that had a TSB and remedy from Toyota. On the driver's side bed bolt closest to the cab, the sheet metal tack welded to the bed has separated and is rusting out. Approximately 7 inches to the drivers side from that bolt. The seam sealer is also cracking. Additionally, the drivers side bed bolt closes to the tailgate has rust bubbling up from underneath approximately 1 inch to the passenger side from the bolt and also along where that sheet metal is tack welded onto the bed.

NHTSA ID

11744041

Incident

Jun 5, 2026

The fuel pump component or system failed or malfunctioned the engine tried cranking but would not start. The problem has been reproduced to an independent service center, where I was notified of a safety recall on Toyota Tundra. No other inspections have been performed. There are no warning lamps messages visible on the vehicle in question. The vehicle will not start until repeated starts are performed. Vehicle idles roughly before regaining normal idle. One other past similar incident of this type has occurred. No other

NHTSA ID

11739464

Incident

May 21, 2026

The contact owns a 2016 Toyota Tundra. The contact stated that while driving at slower speeds, the vehicle stalled while depressing the accelerator pedal. The check engine warning light was illuminated. The vehicle was towed to a local dealer to be diagnosed. The contact was informed that the fuel pump and other fuel pump-related parts needed to be replaced. The vehicle was not repaired because the parts were on back order. The manufacturer was made aware of the failure. The failure mileage was approximately 67,000.

NHTSA ID

11732710

Incident

Apr 8, 2026

Mileage

67,000 mi

The steering rack internal seal inside the steering rack failed/ "blew" per mechanic and is leaking. I could lose my ability to steer at any time while driving my vehicle and wreck. It is currently at the Toyota services center in Gladstone, OR and has been diagnosed. No other representatives have inspected the vehicle. There were no warnings or signs of failure. I had originally taken my truck in to have an oil change and have it checked for a "slow" start up.

NHTSA ID

11719220

Incident

Jan 24, 2026

The power steering went out during routine around-town driving. One moment it was steering fine, the next moment it became extremely difficult and sluggish. There were no warning lights or warning of any sort until the steering wheel started jerking unevenly as I tried to turn. I was able to get control of the vehicle and pull it to the side of the road. There was no difference in the engine noise, and I couldn't see any noticeable fluid leak. I was able to drive the vehicle home, make an appointment with the Toyota dealer, and get the vehicle to the dealership for inspection. The dealership told me after inspection, that the rack and pinion steering was binding internally, and that there was seepage from the right boot. Initially, they told me that the pump should be fine. I authorized them to replace the rack and pinion steering. After which, they told me that the problem seemed to still persist some, and that the pump would have to be replaced also. My total bill came to $3,200, which seemed not unfair. But this whole issue seemed like something that should be noticed as part of a recall. I found the NHTSA recall number. 21V-920, and my truck seemed to match exactly the symptoms spelled out is this recall , but Toyota refused to acknowledge it. My VIN number did not fall within the specified VIN for this recall. I've driven several Toyotas, including another Tundra, a Tacoma, 2 Highlanders and a Sienna, and have been pleased with each vehicle. This Tundra is 10 years old with 95,000 miles, and I've only done expected maintenance and a couple of occasional minor repairs. Those being: - Having the brakes resurfaced - Changing out the alternator In the end, it wasn't a devastating amount of money, but it was an issue that I felt Toyota should have taken care of. I did reach out to them, but because I had already paid for the repairs on the vehicle I needed to drive for work, they refused to talk to me any further. I have the estimate and final bill.

NHTSA ID

11705412

Incident

Dec 4, 2025

My right front headlamp is getting moisture inside the headlamp assembly. It can be inspected any time. Chance that headlamp will not work. Did not take to a dealer.

NHTSA ID

11662959

Incident

May 24, 2025

Odometer Fraud. The contact purchased a 2016 Toyota Tundra. The contact stated while going through prior service paperwork found in the vehicle, he discovered that there was a mileage discrepancy. The vehicle was a private sale. The contact also stated that the vehicle was once sold at a private auction. At the time of purchase, the vehicle mileage was 158,000; however, upon discovery of the service paperwork, the contact discovered that the vehicle mileage was once 250,000.

NHTSA ID

11659434

Incident

May 6, 2025

Mileage

250,000 mi

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.

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.

The air conditioning dye injection tool kit has been developed to aid in identifying the location of air conditioning refrigerant leaks. The procedures outlined in this Service Bulletin aid in locating, inspecting, and repairing refrigerant leaks.

Acid rain results from rainwater or other airborne moisture that become acidic due to industrial chemical impurities in the atmosphere. If these acidic compounds settle on an exposed vehicle, especially the horizontal areas such as the hood, roof, and decklid, significant damage to the painted surfaces can occur. Acid rain damage can typically be identified on vehicles by the presence of stains on the paint surface that resemble hard water spots. Unlike water spots however, acid rain damage cannot be removed by regular washing procedures. Also, because acid rain can etch and soften the paint, normal buffing or polishing repair procedures should not be attempted. This can cause further damage and result in visible depressions in the paint surface. The following are the three major categories of acid rain damage: •Minor damage: requires only buffing to repair. •Moderate damage: usually requires neutralizing, color sanding, and buffing. •Severe damage: extending beyond 1/2 mil of clearcoat on a pearl, metallic, or solid color, requires neutralization, sanding, and repainting. In cases where acid rain damage is minor, neutralization and buffing with a liquid-type paint finessing product may provide an adequate repair. Only specially formulated products outlined in this bulletin should be used for that purpose. Unfortunately, other than minor damage, there is no simple method of determining the actual extent (depth) of acid penetration other than color sanding a representative affected area until there is no visible etching or depressions, followed by measuring the amount of paint removed with either a magnetic or digital-type film thickness gauge. The procedures in this bulletin are intended for use by qualified body/paint technicians and should not be attempted by inexperienced personnel. It is the dealer’s responsibility to protect and maintain the quality of the vehicle’s paint finish after receipt at the dealership prior to the first sale. Perform frequent vehicle washing, as often as daily, during high heat and humidity periods to minimize the potential for paint damage due to acid rain exposure. This is especially important in geographical areas known for high frequency and concentration of acid rain and industrial fallout.

To prevent brake rotor rust from forming during transportation and storage, wheel film will be used instead of a cardboard type of anti-rust cover. The purpose of the wheel film is to shield the disc brake rotor from weather elements and initial rust before the vehicle is delivered to the customer. Consequently, the film should remain on the wheel for as long as possible.

The condition known as acid rain is caused by airborne chemicals or particles in the atmosphere, which mix with rainwater, nighttime dew, or high humidity to form acidic compounds. If these contaminants settle and remain on a painted vehicle surface, especially the horizonal areas of the hood, roof, and decklid, significant damage can occur. This damage is the result of actual etching of the paint and appears as pitting or water spots. As acid rain droplets on the vehicle surface evaporate, the concentration strength of the acid increases, causing deeper and more rapid damage. This evaporation and corrosive action also occur more rapidly on dark colored cars as direct sun heat increases. It is the dealer’s responsibility to protect and maintain the quality of the vehicle’s paint finish after receipt at the dealership prior to the first sale. In areas known for high frequency and/or concentration of acid rain, frequent vehicle washing during high heat or humidity periods will minimize the potential for paint damage caused by acid rain. It is further recommended that either reverse osmosis or deionized water be used to prevent water spotting.