Toyota Rav4 Prime Recalls

The Toyota RAV4 Prime has 11 recalls covering 2021 through 2024 model years, with the most serious being a DC-DC converter defect on 2021-2022 vehicles where an electrical short circuit can cause the converter to overheat and start a fire.

The 2021 model year carries several additional high-severity issues. In cold weather, rapidly pressing the accelerator while driving in EV mode can cause battery voltage to drop suddenly, shutting down the hybrid system and cutting power to the wheels without warning. A separate DC-DC converter defect on 2021 models, located under the rear seat, can also overheat and create a fire risk. Both the cold-weather power loss and the converter fire risk were addressed through software and hardware remedies, though the underlying concern is the same sudden loss of propulsion in traffic.

The 2022 model year has a front passenger seat assembly issue where internal seat components can interfere with the passenger seat sensor, causing it to misread whether an adult is seated. On vehicles equipped with an 8-way power front passenger seat with a seat lifter, this can lead the airbag system to suppress the front passenger airbag during a crash. On other 2022 configurations, the same interference can cause the airbag to deploy incorrectly in a crash. The 2021-2022 model years also have a software issue in the electronic stability control system that can deactivate it without the driver's knowledge, removing a layer of crash protection.

On 2023-2024 models, a software error can cause the rearview camera to freeze or go blank when the vehicle is shifted into reverse, reducing the driver's view behind the vehicle. A separate instrument panel display issue on 2023-2024 vehicles can prevent critical information from appearing on screen while driving.

Going back to 2021, the headlight aiming caps on some vehicles were not properly closed at the factory, allowing the horizontal beam angle to shift and create glare for oncoming drivers.