NHTSA ends Toyota RAV4 battery fire risk investigation after 3-year probe, recall

NHTSA said its probe into the 2013-18 Toyota RAV4, which launched in February 2021 and led to the recall of more than 1.8 million vehicles in North America in November 2023, was closed on Aug. 12.

The investigation by the nation's top safety agency focused on the risk of a sizing issue with the replacement 12-volt batteries. The battery terminal shorted to the battery hold-down frame, potentially causing a sudden loss of electrical power, vehicle stalling or an engine compartment fire.

The RAV4 crossover traditionally is one of Toyota's top-selling vehicles in the U.S. Deliveries rose 33 percent to 248,295 vehicles in the first half of 2024.

NHTSA recorded 101 fires among the vehicles involved in the recall, along with eight injuries, an agency spokesperson told Automotive News.

"The reported fires took place in vehicles known to contain aftermarket batteries or whose age exceeded the expected life of the original equipment battery," NHTSA said in a statement to Reuters.

Following 11 reports related to the battery sizing issue, the agency's Office of Defects Investigation initiated a preliminary investigation in 2021 to understand the factors and frequency of vehicle fires.

A consumer advisory campaign began in November 2021 to inform owners, inspect battery setups and offer discounted replacements.

"Some replacement 12-volt batteries of the size specified for the subject vehicles have smaller top dimensions than others," Toyota said in a statement at the time of the November recall. "If a small-top battery is used for replacement and the hold-down clamp is not tightened correctly, the battery could move when the vehicle is driven with forceful turns.

"The movement could cause the positive battery terminal to contact the hold-down clamp and short circuit, increasing the risk of a fire."

Toyota redesigned the battery retention system, and dealers replaced the battery hold-down clamp, battery tray and positive terminal cover with improved ones at no cost to owners. Toyota notified all customers by late December.

A Toyota spokesperson declined to comment further on the closure of the NHTSA probe.