Toyota has begun mailing letters to owners of certain Toyota and Lexus models regarding the potential for an unsecured or incompatible driver’s floor mat to interfere with the accelerator pedal and cause it to get stuck in the wide-open position.

The letter, in compliance with the National Traffic and Motor Vehicle Safety Act and reviewed by the National Highway Traffic Safety Administration (NHTSA) points out that no defect exists in vehicles in which the driver’s floor mat is compatible with the vehicle and properly secured.

The Toyota finding is consistent with a recent decision by NHTSA denying a request for an additional investigation of unwanted and unintended acceleration of model year 2007 Lexus ES350 vehicles and model years 2002-2003 Lexus ES300. After conducting an extensive technical review of the issue, including interviews with consumers who had complained of unwanted acceleration, NHTSA concluded that “…the only defect trend related to vehicle speed control in the subject vehicles involved the potential for accelerator pedals to become trapped near the floor by out-of-position or inappropriate floor mat installations.”

This is the sixth time in the past six years that NHTSA has undertaken such an exhaustive review of allegations of unintended acceleration on Toyota and Lexus vehicles and the sixth time the agency has found no vehicle based cause for the unwanted acceleration allegations.

“The question of unintended acceleration involving Toyota and Lexus vehicles has been repeatedly and thoroughly investigated by NHTSA, without any finding of defect other than the risk from an unsecured or incompatible driver’s floor mat,” said Bob Daly, TMS senior vice president.

“Toyota takes public safety seriously. We believe our vehicles are among the safest on the road. Our engineers are working hard to develop an effective remedy that can help prevent floor mat interference with the pedal. As soon as it is ready, we will notify owners of the relevant models to bring their vehicle to a dealer for the necessary modification at no charge,” Mr. Daly added.

In the recently completed investigation, NHTSA conducted extensive testing on a Lexus ES350. The agency reported that:

“The vehicle was fully instrumented to monitor and acquire data relating to yaw rate, speed, acceleration, deceleration, brake pedal effort, brake line hydraulic pressure, brake pad temperature, engine vacuum, brake booster vacuum, throttle plate position, and accelerator pedal position. Multiple electrical signals were introduced into the electrical system to test the robustness of the electronics against single point failures due to electrical interference. The system proved to have multiple redundancies and showed no vulnerabilities to electrical signal activities. Magnetic fields were introduced in proximity to the throttle body and accelerator pedal potentiometers and did result in an increase in engine revolutions per minute (RPM) of up to approximately 1,000 RPM, similar to a cold-idle engine RPM level. Mechanical interferences at the throttle body caused the engine to shut down.”

The Toyota letter is an interim notice to owners of a future voluntary safety recall campaign. The following models are affected:

• 2007 – 2010 Camry
• 2005 – 2010 Avalon
• 2004 – 2009 Prius
• 2005 – 2010 Tacoma
• 2007 – 2010 Tundra
• 2007 – 2010 ES350
• 2006 – 2010 IS250 and IS350

Until Toyota develops a remedy, it is asking owners of affected Toyota and Lexus models to take out any removable driver’s floor mat and NOT replace it with any other floor mat.

The Toyota letter also informs owners of what to do if they experience accelerator pedal interference, general floor mat warnings and proper floor mat application information. Owners who have further questions are asked to visit http://www.toyota.com/floormats or http://www.lexus.com/floormats where the owner letter in its entirety can also be viewed. The most recent NHTSA report can be viewed on these websites as well.

Toyota, still reeling from it’s largest-ever recall, has a new potential problem on the horizon. The NHTSA is investigating complaints against the 2000-2001 model year Toyota Tundra. NHTSA has received 20 reports relating to spare tire separation and brake system failures caused by severe frame corrosion.

There have been 15 reports alleging that the under-body mounted spare tire separated from the crossmember due to corrosion. There have been an additional 5 reports of broken brake lines at the proportioning valve located on the driver’s side of the rear crossmember at the upper shock mount.

There were over 200,000 Tundras sold in the affected model years.

The National Highway Traffic Safety Administration has alerted Lexus and Toyota owners about conditions that could cause the accelerator to get stuck open under certain conditions. The agency strongly recommends taking out removable floor mats on the driver’s side in certain models and not to replace them with any other mat, either from Toyota or any other brand.

“This is an urgent matter,” said U.S. Transportation Secretary Ray LaHood. “For everyone’s sake, we strongly urge owners of these vehicles to remove mats or other obstacles that could lead to unintended acceleration.”

NHTSA notes that there continue to be reports of accelerator pedal clearance issues which provide the potential for an accelerator pedal to get stuck in the full open position. A stuck accelerator may result in very high vehicle speeds and a crash, which could cause serious injury or death.

Toyota will soon launch a safety recall of various model year vehicles to redress the problem. However the safety agency warned owners to remove all driver-side floor mats from the models listed below immediately as an interim safety measure in advance of the recall.

Toyota and Lexus vehicles affected by this consumer alert are:

2007-2010 Camry
2005-2010 Avalon
2004-2009 Prius
2005-2010 Tacoma
2007-2010 Tundra
2007-2010 ES 350
2006-2010 IS 250 and IS350

This recall will affect roughly 3.8 million vehicles, representing the largest US recall in Toyota history and affected vehicle owners will be notified beginning this week.

The recall was sparked by a fiery crash that killed four family members in August near San Diego.

Toyota and the NHTSA recommend that owners of affected vehicles immediately remove the driver’s-side floor mat as a precaution. If the floor mat is in place, Toyota warns that if the vehicle continues to accelerate rapidly after releasing the accelerator pedal, this could be an indication of floor mat interference. If this occurs, Toyota recommends the driver take the following actions:

First, if it is possible and safe to do so, pull back the floor mat and dislodge it from the accelerator pedal; then pull over and stop the vehicle.

If the floor mat cannot be dislodged, then firmly and steadily step on the brake pedal with both feet. Do NOT pump the brake pedal repeatedly as this will increase the effort required to slow the vehicle.

Shift the transmission gear selector to the Neutral (N) position and use the brakes to make a controlled stop at the side of the road and turn off the engine.

If unable to put the vehicle in Neutral, turn the engine OFF, or to ACC. This will not cause loss of steering or braking control, but the power assist to these systems will be lost.

-If the vehicle is equipped with an Engine Start/Stop button, firmly and steadily push the button for at least three seconds to turn off the engine. Do NOT tap the Engine Start/Stop button.

-If the vehicle is equipped with a conventional key-ignition, turn the ignition key to the ACC position to turn off the engine. Do NOT remove the key from the ignition as this will lock the steering wheel.

Toyota is considering a recall involving headlights on the Toyota Prius. The HID bulbs on some Prius models can cost upwards of $1,000 to replace when they fail, prompting a slew of complaints by affected Prius owners as well as a lawsuit that may become a class-action suit.

The NHTSA has begun a preliminary investigation after receiving more than 300 complaints regarding the issue. Toyota claims that it is cooperating with the NHTSA but has refused to comment on the possibility of a recall.

Toyota will launch an Equipment Safety Recall with the National Highway Traffic Safety Administration (NHTSA) involving approximately 39,100 Toyota Stainless Steel Exhaust Tip retention Clamps. This optional accessory was designed specifically for 2008 model year Highlander and Highlander HV vehicles sold in the United States.

Due to improper heat treatment, the original clamp used to secure the stainless steel exhaust tip to the exhaust pipe may develop microscopic cracks. If this occurs, the crack may expand causing the clamp to break and in the worst case the exhaust tip may fall off.

There are approximately 39,100 accessory kits that may be affected by this condition. Because this accessory is installed at the Toyota vehicle processing centers and dealers, and is available over-the-counter, all of approximately 121,000 vehicle owners will be notified.

There have been ten reported incidents of this condition in the United States; no other Toyota or Lexus vehicles are involved in this recall.

Toyota will inform owners of the involved vehicles with a Safety Recall notification via first-class mail beginning in early May. The notification will include inspection instructions for owners to determine if their vehicle is equipped with this accessory. Affected owners are requested to contact their local Toyota dealer for inspection and repair.

Customers with questions or concerns should contact the Toyota Customer Experience Center at 1-800-331-4331.

Toyota Motor Sales will launch a safety recall with the National Highway Traffic Safety Administration (NHTSA) involving approximately 214,500 Lexus vehicles.

On certain 2006 through 2008 model year GS300/350, IS250/350, and LS460/460L vehicles, Lexus has determined that some ethanol fuels with a low moisture content may corrode the internal surface of the fuel delivery pipes. If this condition occurs, the Malfunction Indicator Light (MIL) in the combination meter may illuminate. Over time, the corrosion may create a pinhole in the fuel delivery pipes resulting in fuel leakage.

Lexus dealers will replace the fuel delivery pipes with newly designed components. No other Lexus or Toyota vehicles are involved.

Lexus will inform owners of the involved vehicles with a safety recall notification via first-class mail beginning in late January. Owners are requested to contact their local Lexus dealer for diagnosis and repair at no charge.

Customers with questions or concerns should contact the Lexus Customer Assistance Center at 1-800-255-3987.