Toyota has announced a recall in the United States for the 2023-2024 Sequoia Hybrid models due to an issue with the tow hitch cover that could potentially fall off while driving. This problem has prompted safety concerns, as a loose or detached tow hitch cover could create a road hazard, increasing the likelihood of an accident involving other motorists. The problem stems from the design of the tow hitch cover, which is made of resin and is attached to the rear bumper using molded clips. However, the attachment design has proven to be insufficiently robust, leading to the possibility that the cover may not remain securely in place.
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The recall affects a total of 43,395 Sequoia Hybrid vehicles that were manufactured between August 31, 2022, and July 23, 2024. Despite this large number of affected vehicles, Toyota has not provided a precise estimate of how many of these cars actually have the defective tow hitch cover. The problem came to Toyota's attention after two field reports were submitted by customers who experienced the tow hitch cover falling off their vehicles while on the road. Following these reports, Toyota launched an investigation and discovered that the issue was due to poor engagement at multiple clip locations on the bumper. Specifically, it was found that the holes in the bumper were incorrectly sized, leading to an inadequate connection between the tow hitch cover and the bumper.
In response to this discovery, Toyota undertook efforts to improve the design of the tow hitch cover between August 2023 and June 2023. These design improvements were then incorporated into the production of new Sequoia Hybrid models starting in early July 2024. Despite these corrective actions, the issue had already affected a significant number of vehicles, with 1,024 warranty claims related to the faulty tow hitch cover being filed in the United States by August 20.
Toyota is addressing the issue by alerting owners of the affected Sequoia Hybrid models, with notifications beginning on October 5, 2024. The automaker has instructed its dealers to replace the tow hitch cover on all recalled vehicles with the newly updated part that features the improved design. Additionally, the dealers will modify the rear bumper to ensure a more secure attachment of the tow hitch cover, thereby preventing future incidents.
This recall highlights the importance of rigorous quality control in vehicle manufacturing, particularly when it comes to safety-related components. Toyota's response aims to rectify the issue promptly to minimize any potential risks to drivers and other road users.