2016 Toyota Avalon

The defect

Toyota Motor Engineering & Manufacturing (Toyota) is recalling certain 2011-2019 Corolla, 2011-2013 Matrix, 2012-2018 Avalon, and 2013-2018 Avalon Hybrid vehicles. During certain crashes, the air bag electronic control unit (ECU) may malfunction, possibly disabling the deployment of the air bags and/or seat belt pretensioners.

The risk

In the event of a crash, air bags and/or seat belt pretensioners that do not deploy as intended may increase the risk of injury.

The remedy

Toyota will notify owners, and dealers will inspect the ECU and install a noise filter between the air bag control module and its wire harness, as necessary, free of charge. Owners were notified of the safety risk beginning March 2, 2020. A second letter notifying owners of the remedy repair will be mailed between March 16, 2020 and June 27, 2020. Owners may contact Toyota customer service at 1-888-270-9371. Toyota's numbers for this recall are 20TB03, 20TA03 and 20TA05.

Toyota Motor Engineering & Manufacturing · up to 2,891,976 vehicles across all model years covered

The defect

Toyota Motor Engineering & Manufacturing (Toyota) is recalling certain model year 2016 Avalon, and 2017 Camry vehicles manufactured August 3, 2016, to September 12, 2016. The front passenger knee air bag module may have been attached to the lower instrument panel with incorrect fasteners.

The risk

If the air bag was installed with incorrect fasteners, the fasteners may become loose over time, affecting the air bag deployment and increasing the risk of injury.

The remedy

Toyota will notify owners, and dealers will inspect the fasteners, and if necessary, replace the instrument panel brace and body bracket and reattach the air bag assembly, free of charge. The recall began on February 8, 2017. Owners may contact Toyota customer service at 1-800-331-4331. Toyota's number for this recall is G05.

Toyota Motor Engineering & Manufacturing · up to 12 vehicles across all model years covered

The defect

Toyota Motor Engineering & Manufacturing (Toyota) is recalling certain model year 2016 Avalon and Camry vehicles manufactured November 30, 2015 to March 4, 2016. The occupant classification system (OCS) that activates or deactivates the front passenger seat air bag system may have been improperly calibrated. As a result, the front passenger air bag and the front passenger knee air bag may not deploy as intended in certain crash scenarios. As such, these vehicles fail to comply with Federal Motor Vehicle Safety Standard (FMVSS) number 208, "Occupant Crash Protection."

The risk

Air bags that do not deploy as intended during a crash increase the risk of injury.

The remedy

Toyota will notify owners, and dealers will recalibrate the OCS, free of charge. The recall began by May 13, 2016. Owners may contact Toyota customer service at 1-888-270-9371. Toyota's number for this recall is G0J.

Toyota Motor Engineering & Manufacturing · up to 58,515 vehicles across all model years covered

Closed engineering analysis · opened April 19, 2019 · closed September 19, 2024 · led to recall 20V024

the air bags

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.

95,500 miles

The contact owns a 2016 Toyota Avalon. The contact stated that while driving approximately 70 MPH, the sunroof glass shattered. The contact stated that there was no glass inside the vehicle because the sunroof shade was in the closed position. The vehicle was not diagnosed or repaired. The manufacturer was not notified of the failure. The failure mileage was approximately 95,500.

NHTSA complaint 11691211. Filed by an owner and not verified by NHTSA or by us.

The manufacturer is no longer producing OEM windshield that comply with the a DAS features which are now in operable because my windshield will not calibrate after replacement because there is not an OEM windshield available. I have contacted Toyota. I have also searched everywhere in the states for an OEM windshield Toyota has tried to calibrate the replacement which is aftermarket, as well as the Auto Glass installer to no avail. Toyota is no longer manufacturing the OEM windshield which is needed for the safety features to function properly. The car should be recalled for a manufacturer defect.

NHTSA complaint 11576871. Filed by an owner and not verified by NHTSA or by us.

84,575 miles

The contact owns a 2016 Toyota Avalon equipped with Cooper Tires, Tire Line: CS5 Ultra Touring, Tire Size: 215/55/R17, DOT Number: U93R1CU1820. The contact stated that while driving at various speeds, the front end of the vehicle was shaking abnormally without warning. The contact took the vehicle to a tire shop and was informed that the tread on the driver’s and passenger’s side tires were separating. The contact's husband drove the vehicle to the original tire shop where the tires were purchased and was offered a store credit for the replacement tires. The manufacturer was not made aware of the failure. The tire was a replacement tire. The tire failure mileage was approximately 6,000, and …

NHTSA complaint 11520951, quoted in part. Filed by an owner and not verified by NHTSA or by us.

60,000 miles

The contact owns a 2016 Toyota Avalon. The contact stated that while driving at an undisclosed speed, the brake pedal was depressed; however, the vehicle failed to stop immediately and made an abnormal sound. Additionally, the center console was extremely hot, and the driver's side seat electric panel cover had detached. The contact inspected the driver's side seat and noticed there was rust on the seat. The vehicle was taken to the dealer where the brake pads were cleaned; however, the mechanic was unable to duplicate the failure for the center console. The vehicle was not repaired. The manufacturer was not made aware of the failure. The failure mileage was approximately 60,000.

NHTSA complaint 11506672. Filed by an owner and not verified by NHTSA or by us.

Clear

NHTSA complaint 11499774. Filed by an owner and not verified by NHTSA or by us.