NHTSA Complaint #11696848 — 2012 TOYOTA PRIUS

While driving 60 mph in highway, ABS, traction control and brake lights lit up and vehicle lost its effective braking power. There were no prior warnings prior to this failure. It was a sudden incident. Since it wasn't rush hour, I could safely reduce speed and bring the car to stop. Situation could have been much different if it was normal hours. After taking the car to dealership, it indicated DTC code 1391, Brake Assembly Failure. The car was fixed at dealership at cost of $3,000. When researched further, it appeared that there is broader pattern of failures. Numerous reports have been made by owners of 2010–2015 Toyota Prius, Prius PHV, 2012–2015 Prius V, 2012–2014 Camry Hybrid, and 2013–2015 Avalon Hybrid vehicles, all of which share the same brake booster pump assembly design manufactured by Advics Co., Ltd. Dealerships, including Capistrano Toyota and Claremont Toyota in California, have previously petitioned NHTSA regarding this very defect. Their 2019 letter to the agency documented that Toyota: * Knowingly excluded hundreds of thousands of hybrids from prior safety recalls (DOH 13V-235 and KOL 19V-544) despite identical failures. *Issued “post-failure” repair programs (Warranty Enhancements ZJB, ZKK, ZKC, ZLM, 20LE03, 23TE06 and 23TE07) only after owners experienced brake failure. * Identified the same DTC codes (C1252, C1253, C1256, C1391, U0293) in both recalled and unrecalled vehicles—codes that correspond to accumulator leaks, loss of brake pressure, and failure of brake assist and stability control systems. * Admitted through Technical Service Bulletin TSB-0130-19 that these defects caused loss of hydraulic pressure, increased stopping distance, and total loss of brake assist in affected hybrids. In short, the defect pattern across multiple hybrid models is identical to those already recognized by Toyota and NHTSA under prior recall campaigns, but for reasons unexplained, Toyota limited the recall population and left many consumers unprotected