Toyota Recalling More Than 1 Million Vehicles

On September 9, Toyota and National Highway Transportation Safety Administration (NHTSA) have cited three separate voluntary recalls, involving a total 1,015,249 built between 2006 and 2011. The recalls were only the latest in a long list by the Japanese auto giant.

The first recall is not only one of the year’s larger safety-related recalls but it also marks the second time the Japanese giant will attempt to fix a problem with the rear suspensions on 780,000 crossovers and hybrids that could lead to a crash. Toyota found that a fix it put in place in August 2012 didn’t solve the problem and will have to recall the vehicles again. The two vehicles covered by the latest service action are the 2010 Lexus HS250 hybrid and the 2006 through 2011 Toyota RAV4 crossover, the latter one of the maker’s most popular models.

The Lexus GS 350's engine can suddenly stall due to loose bolts on the cars Variable-Valve Timing system gear assembly. The original problem involved a wobbling rear suspension arm that could, over time, rust out. That could lead to a suspension failure and, in a worst-case scenario, a crash. The maker has since discovered that the nuts it used to adjust the alignment of the rear wheels on the two vehicles during the August 2012 recall were not tightened properly.

The maker has notified NHTSA it will now have to recall the same, 780,000 vehicles to inspect for damage. The nuts will now be properly tightened and Toyota will take the additional step of sealing the rear lower suspension arms with an epoxy coating designed to prevent corrosion. The maker says it will have to stage the recall due limited parts availability, with the entire recall process likely to be completed by mid-February. The inspection process actually began in June and Toyota told NHTSA that the vast majority of those vehicles it looked at did not need further repairs. But it has no way of being sure which vehicles do need the fix without conducting the inspection.

In addition, Toyota, which seemed well on its way to re-establishing its peerless reputation for quality, also said it was recalling 133,091 hybrids from 2006-2010, including Highlander and Lexus RX 400h models. Toyota said there was a potential for shutting down of the hybrid system, causing the vehicle to stall. Transistors within the hybrid system’s inverter assembly can experience heat damage due to variations in characteristics of the transistors built in parallel circuits. Should this occur, various warning lights on the instrument panel will illuminate, and in most cases the vehicle will enter "limp home mode." In limited instances, the hybrid system will shut down and resulting in the vehicle stopping while the vehicle is being driven.

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