Toyota Recalls 75,000 Prius

13 October 2005

Toyota is recalling (“launching a Special Service Campaign”) 75,000 model year 2004 and early 2005 model year Prius sold in the US because an issue with the powertrain’s program logic may cause the engine to stall.

The National Highway Traffic Safety Administration (NHTSA) began investigating reports of such engine stalling without warning earlier in the summer after receiving 33 complaints. (Earlier post.)

NHTSA closed its investigation once Toyota indicated it would institute the recall.

On the involved vehicles, an issue with the program logic in the Electronic Control Module (ECM) system may cause some or all of the following warning lights to illuminate: Master, Hybrid System, Engine, Vehicle Stability Control, and Brake. If this occurs, the vehicle will enter a “fail-safe” mode which stops the engine, allowing limited operation via the electric motor.

The electrically-powered brake and steering operation will continue to function normally if this condition occurs. The electric motor will also provide enough power to allow the driver to pull the vehicle over and away from traffic. Once the vehicle is stopped, the driver may be able to restart the gasoline engine in the vehicle by pushing the start button, according to Toyota.

Toyota will inform owners of the involved vehicles with a Special Service Campaign notification letter sent via first class mail beginning in late-October. Owners are requested to contact their local Toyota dealer for diagnosis and repair upon receiving their notification. Toyota will reprogram the ECM system at no charge to the owners of the vehicle. Also, in certain vehicles a special dielectric grease will be applied, at no charge, to a connector for the transaxle, which may cause a similar condition.