Toyota Avalon Recalls

The Toyota Avalon has 32 recalls spanning the 1997–2021 production run, with the most serious recent issue being a fuel pump defect on 2019–2020 models where the pump can fail and stall the engine without warning while driving.

The most recent production years carry several safety-critical issues. On 2020–2021 models, the passenger seat sensor that determines whether to activate or suppress the front passenger airbag can malfunction, potentially leaving the airbag inactive in a crash. A separate issue on 2020–2021 vehicles involves breakaway pins in the steering column that may have been damaged during production, which can interfere with the driver's airbag performance in a crash. The 2020 Avalon Hybrid specifically has a recall for engine castings that can develop cracks, allowing coolant to leak internally and cause the engine to overheat and stall. On 2019 Avalon Hybrid models, a fuel filler pipe that was not properly reconnected to the fuel tank can leak fuel and create a fire risk. The 2019 model year also has an airbag control unit that can incorrectly detect a fault during startup and fail to deploy airbags in a crash.

The 2013–2018 model years share a recall where the airbag control unit can malfunction during certain crashes and disable airbag and seatbelt pretensioner deployment. On 2013–2015 models equipped with the optional pre-collision system, the system can trigger unexpected hard braking without a real obstacle ahead. The 2016 model year has two airbag-related issues: the front passenger knee airbag may have been installed with incorrect fasteners that can loosen over time and affect deployment, and the passenger seat sensor may have been improperly calibrated, causing the passenger airbag to behave incorrectly in a crash. The 2012 model has a recall where replacement seat belt buckles can falsely signal the belt as always buckled, potentially suppressing airbag deployment in a crash. On 2011–2012 models, a trunk-mounted subwoofer can develop an electrical short in the audio amplifier that causes it to overheat and create a fire risk.

Going further back, 2005–2010 models distributed through Southeast Toyota have aftermarket seat heaters whose wiring can short and cause the seat to burn. The 2005 model year alone has three separate issues: the accelerator pedal can stick in a depressed position and cause unintended acceleration, and the steering yoke was not welded to the steering shaft on some vehicles, which can cause complete loss of steering. The 2003–2004 model years have a supplemental restraint system defect that can cause airbags and seatbelt pretensioners to deploy unexpectedly without a crash, startling the driver. On 2000–2004 models, a crack can develop in the steering lock bar and eventually cause the steering wheel to lock while driving. The 2000 model year has a rear axle shaft that can break after extended use and cause a wheel to separate from the vehicle. The 1997 model has a brake booster vacuum hose that can freeze in very cold conditions and eliminate power brake assist.