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Toyota RAV4 Prime power converter can overheat and catch fire

NHTSA campaign 23V478000 · Reported 2023-07-12 · Toyota Motor Engineering & Manufacturing

critical How serious is it? About this label

This is serious because it can lead to a vehicle fire; the notice does not tell owners to stop driving, but you must follow Toyota's warning not to charge in cold weather until the converter is replaced.

What's wrong, in plain English

A part inside the box that converts the big battery's power for the car's regular electrical system may have been damaged when it was built. That damage can cause an electrical short, which can make the part overheat and start a fire. Until the repair is done, Toyota says do not charge the vehicle when the outside temperature is below 41 degrees Fahrenheit, or expected to drop below it. A dealer replaces the part free.

What you should do

1. Look up your VIN at nhtsa.gov/recalls to confirm your vehicle is affected. 2. Stop charging whenever it is, or will be, colder than 41°F outside. 3. Call your Toyota dealer or Toyota customer service at 1-800-331-4331 (recall 23TB07) and have the converter replaced free of charge.

Affected vehicles (2)

Who to contact

Toyota — official Toyota recall lookup

Customer service: 1-800-331-4331

Any franchised dealer for the brand can do the repair. Phone numbers are taken from manufacturer sites and recent NHTSA notices; if one has changed, the number in your own recall letter is the one to use.

The bigger picture

Official notice

Component
ELECTRICAL SYSTEM:PROPULSION SYSTEM:DC/DC CONVERTER
Summary
Toyota Motor Engineering & Manufacturing (Toyota) is recalling certain 2021-2022 RAV4 Prime and 2022 Lexus NX450h+ plug-in hybrid electric (PHEV) vehicles. The electric current rectifying module contained within the DC-DC converter may have been damaged during production, which can result in an electrical short-circuit.
Safety risk
A short circuit can cause the DC-DC converter to overheat, increasing the risk of a vehicle fire.
Remedy
Owners are advised not to charge their vehicles when the ambient air temperature is below or expected to drop below 41 degrees Fahrenheit (5 degrees Celsius). Dealers will replace the DC-DC converter, free of charge. Owner notification letters were mailed December 29, 2023. Owners may contact Toyota's customer service at 1-800-331-4331. Toyota's number for this recall is 23TB07/23LB01.

Verify your specific vehicle by VIN at nhtsa.gov. Recall repairs are free of charge by law.