Toyota is facing one of its most expensive and complex recalls after discovering a defect in the V-6 twin-turbocharged engines powering both the Tundra pickup trucks and the luxury Lexus LX SUVs. This issue affects vehicles from the 2022 and 2023 model years, specifically those produced between November 2021 and February 2023, and for the Lexus LX, from July 2021 to November 2022.

What’s wrong with these engines?

The defect that triggered this large-scale recall can cause the engine to stall suddenly while driving, significantly increasing the risk of a crash. The root of the problem stems from machining debris left inside the engine during production, which can lead to engine knocking, rough operation, difficulty starting, and, in the worst cases, total loss of power.

In May 2024, Toyota notified the National Highway Traffic Safety Administration (NHTSA) of this issue. At the time, the company estimated that only 1% of the 102,092 potentially affected vehicles might exhibit the defect. However, this figure was largely due to limitations in NHTSA’s reporting system, where Toyota explained that it was unable to provide an accurate estimate of the number of vehicles affected.

Drastic solution: complete engine replacement

Two months after the initial filing, Toyota still had not determined exactly how many vehicles were affected, leading to a radical decision: replace the engines in every potentially impacted vehicle. This means swapping out the engines in over 100,000 vehicles, including approximately 98,600 Tundras and 3,500 Lexus LX SUVs.

So far, this solution only applies to non-hybrid versions of the 3.4-liter V-6 twin-turbocharged engines (designated V35A). The hybrid Tundra models are not included in this recall because, in the event of an engine failure, their electric motors can still provide power to the vehicle.

How the issue was discovered

The investigation began in March 2022, when a customer reported a sudden engine stall. Toyota found that the main engine bearings had seized. More reports followed, and as Toyota continued its investigation, it became clear that machining debris was responsible for the engine failures.

By 2023, Toyota had accumulated 166 technical reports, and 824 warranty claims related to this problem. This led the company to issue a voluntary recall of the affected vehicles. Even engines that initially appeared to be in good condition were found to have issues after thorough inspection.

Financial impact of the recall

Replacing over 100,000 engines will come at a significant cost to Toyota. Beyond the price of the new engines themselves, the company will also need to cover labour costs for removing the faulty engines and installing the replacements. There’s a concern that this massive recall could affect the production of new vehicles, as manufacturing capacity may need to be redirected to produce replacement engines for the recall.

Despite the high cost, Toyota has been praised for taking such a comprehensive approach to safety, even though it’s uncertain how many vehicles are actually at risk. The company plans to send notices to vehicle owners before the end of the month, informing them about the recall and the next steps.

Toyota’s commitment to long-term customer trust

This recall highlights Toyota’s dedication to maintaining long-term customer trust by addressing issues head-on, no matter the scale or cost involved. Although only a fraction of the affected vehicles may experience engine failure, Toyota’s decision to replace over 100,000 engines is a testament to its proactive approach to safety and reliability. By opting for a complete engine replacement rather than a smaller-scale fix, Toyota is reinforcing its brand reputation as one that prioritizes customer well-being over short-term financial concerns. In a competitive market where reliability is a key selling point, this recall serves as a clear message: Toyota is willing to go the extra mile to ensure the performance and safety of its vehicles remain uncompromised.

Toyota has taken a bold and proactive stance by addressing this engine defect in their V-6 twin-turbocharged vehicles. Replacing all potentially affected engines, while costly, ensures that customer safety is the top priority. By doing so, the company demonstrates a strong commitment to resolving quality issues, even if the financial co

nsequences are significant.

– Union Rayo