Toyota has announced a recall of more than 100,000 vehicles, including certain Tundra pickup trucks and Lexus LX SUVs, due to a potentially catastrophic engine failure. The recall affects models built in 2022 and 2023, all equipped with the V35A six-cylinder engine. This recall follows an investigation by the National Highway Traffic Safety Administration (NHTSA).
The Root of the Problem: Debris in the Engine
According to the NHTSA, the issue stems from manufacturing debris that was not properly cleared out during production. This debris can contaminate the engine, specifically affecting the crankshaft main bearings. Toyota’s internal documentation provides a detailed explanation:
“The subject vehicles are equipped with a specific V35A engine that contains crankshaft main bearings which allow the crankshaft to rotate within the engine assembly while running. During a specific production period, there is a possibility that engine machining debris of a particular size and amount may not have been cleared from the engine during manufacturing and subsequently contaminated the engine assembly during the production process. For these engines in the subject vehicles, the pressure on the main bearings due to the engine configuration is such that, if the aforementioned machining debris adheres to the bearings and operation of the engine continues at higher loads over time, failure of the bearings may occur.”
Consequences of Engine Failure
The contamination of the main bearings can lead to several severe issues, including engine knocking, rough running, failure to start, and a complete loss of motive power. The implications of such failures are dire, particularly if a vehicle loses power at high speeds, significantly increasing the risk of accidents.
A notice to U.S. dealerships elaborated: “In the involved vehicles, this can lead to potential engine knocking, engine rough running, engine no start and/or a loss of motive power. A loss of motive power while driving at higher speeds can increase the risk of a crash.”
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Toyota initially became aware of the problem in June 2022, after examining two pickup trucks with seized engines. Continued analysis and engine dissections were carried out until May 2024, during which time Toyota implemented changes to its engine manufacturing processes to reduce contamination risk.
“As of May 20, 2024, based on a diligent review of records, Toyota’s best engineering judgement is that there are 166 Toyota Field Technical Reports and 824 warranty claims on the engines in the subject vehicles that have been received from U.S. sources that relate or may relate to this condition and which were considered in the decision to submit this report,” Toyota’s documentation stated.
While Toyota is currently developing a remedy to address the issue, it has assured vehicle owners that all recall work will be performed at no cost to them. Additionally, Toyota has committed to reimbursing owners who have already paid for repairs related to this engine problem.
This recall is part of a broader context of increased scrutiny of automotive safety and manufacturing standards. Notably, Japanese authorities have been investigating irregularities in vehicle certification processes, impacting several automakers including Toyota, Mazda, Honda, Suzuki, and Yamaha. These investigations have revealed issues such as flawed or manipulated data submissions for vehicle certification.
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The fallout from these certification scandals is significant, with potential repercussions for production and sales. Analysts suggest that while Toyota may face pressure to strengthen governance, the impact on sales might be limited due to the lack of alternatives in the Japanese market.
James Hong, head of mobility research at Macquarie, noted, “When it comes to actual sales in the Japan market, the damage will be manageable or quite small because consumers have no alternatives in Japan.”
The recall of over 100,000 Tundra trucks and Lexus LX SUVs by Toyota underscores the critical importance of stringent manufacturing processes and thorough quality control. As the company works on a solution and compensates affected owners, the automotive industry as a whole faces increasing pressure to maintain high safety standards amidst growing scrutiny and regulatory challenges.
To see if your vehicle is involved in a safety recall visit Toyota.com/recall or nhtsa.gov/recalls and enter your Vehicle Identification Number (VIN) or license plate information.
