2021 TOYOTA RAV4 Electrical System Problems

This complaint is being filed as a follow-up to a previously submitted NHTSA complaint regarding door lock failures on my 2021 Toyota RAV4 Hybrid. Since the original complaint, a second door has now failed. In addition to the front passenger door, the rear passenger-side door will no longer lock or unlock electronically using the key fob or interior power lock button and must be locked manually. When attempting to lock the vehicle, the vehicle emits a warning beep indicating a door is unsecured, even though some doors appear locked. Upon inspection, the rear passenger door was found unlocked. This issue appears to be progressive, affecting multiple doors. Doors may appear locked when they are not, creating a security concern.

Driver door lock actuator. When using the vehicles remote key, the driver door does not lock and unlock with the rest of the vehicles locks. This failure can cause theft of personal property in the vehicle or theft of the vehicle itself. The problem has been confirmed by other toyota owners with similar models. No warning lights of the problem appeared.

I am reporting a safety defect involving the front passenger door lock actuator on my 2021 Toyota RAV4 XLE Hybrid. The front passenger door will not lock or unlock using the key fob or the interior power door lock button. The door must now be locked manually. This defeats the vehicle’s automatic locking system and creates a safety and security concern. This condition prevents all doors from being secured properly when driving or when parked. A passenger may believe the door is locked when it is not, increasing the risk of unauthorized entry, theft, or passenger safety issues. The failure occurred during normal use and without warning. The vehicle has been properly maintained. I have learned that multiple Toyota RAV4 owners have reported similar door lock actuator failures, indicating a potential widespread defect. This issue occurred shortly after the factory warranty expired. Due to the safety implications, I believe this...

‘Voltage abnormality, power steering low’ error message has appeared three separate times. All while vehicle is idle at stop light or parked, last incident car was unable to restart immediately. All dashboard lights came on, including message saying parking hold unavailable. Mechanic confirmed no issues with 12v battery health and unable to recreate issue. Loss of power is risk to safety, possible draining of battery due to unknown issue

While driving at highway speeds (approx. 65 MPH), the vehicle suffered a sudden and catastrophic loss of motive power. The "Hybrid System Malfunction" warning illuminated, followed immediately by a "Check Engine" light. The vehicle entered a fail-safe mode, then completely shut down. The steering wheel locked, making it extremely difficult to maneuver the vehicle to the shoulder in a dark, remote area with freezing temperatures. This presented an immediate life-safety risk to all occupants. Following the incident, the vehicle was presented to two separate authorized Toyota dealerships in the US for emergency assistance. Both failed to provide the standard of care required for a high-voltage safety failure. The first dealer refused to perform even a basic safety inspection or intake the vehicle, stating they had no hybrid technicians on weekends. They turned the vehicle away without safety warnings, forcing the operation of a chemically failing vehicle on public roads. The...

Message "Voltage Abnormality Steering Power Low" was displayed several times while stopped at traffic lights and the auto stop/start engine feature was engaged. Took vehicle to dealership nothing was done since they could not replicate the issue.

On May 1, 2025, my 2021 Toyota RAV4 Hybrid displayed an SRS Airbag malfunction warning (Recall 23TA15). The passenger airbag was disabled, making the vehicle unsafe to drive. Toyota had announced this recall in December 2023, but I never received any notification. When I contacted Toyota on May 9, 2025, I was told there were no parts available and was even offered a $200 paid inspection instead of a free recall repair. My vehicle remained at the dealership from May until September 29, 2025, without any available remedy. During this period, I continued paying my auto loan and insurance for a car I could not use. Toyota also failed to disclose my right to a free rental vehicle; I only received temporary rentals (Camry, later Tacoma) after repeated demands, and they did not meet my transportation needs. While the airbag recall was still unresolved, a second safety recall (25TD01 –...

1. My vehicle had a hybrid warnings and stopped running altogether, but the issue went away after clearing the codes. It came back at 105000mi, Toyota won't help with the $6000 repair. High Voltage Under Floor Cable and Traction Motor Cable on my vehicle (2021 Hybrid Rav4 XLE registered in Massachusetts) is affected by excessive and dangerous corrosion due to a Toyota design issue. 2. The vehicle could suddenly shut off at highway speeds per Matt with Service at Autofair Toyota Tewksbury. Sudden stoppage or deceleration may result in fatal collisions at speed. This failure also leads to fatally high-voltage energizing of the chassis and other frame components in some cases. 3. This is a known design flaw on Toyota hybrid, high-voltage cables/connectors, leading to excessive corrosion and dangerous failure of the hybrid system. There is an extended Toyota customer support program (CSP: 22TE09) valid through 8 years or 100000mi....

While parked in a commercial lot on [XXX] around [XXX], I noticed smoke coming from the front of the vehicle while sitting inside. There was a strong burning rubber smell. I exited and saw flames coming from beneath the front left bumper, directly under the fog light area. I had arrived at the location about 30 minutes earlier. I opened the hood from inside the vehicle, stepped back, and called 911. The fire rapidly engulfed the front of the vehicle. Firefighters arrived within 10 minutes and extinguished the fire. Police responded and created a report. Three nearby vehicles also sustained fire damage. The vehicle had previous front-end repairs (driver side bumper and fog light) and was well maintained. The vehicle had not shown any warning lights or messages prior to the fire. I believe the fire originated from an electrical or engine component and the vehicle is available for inspection...

Steering power low message appears and engine completely stops.

The High voltage floor underwire harness and rear traction motor cable corroded. This caused many if the vehicles sensors to fail completely including the tire pressure monitor system, adaptive cruise, collision avoidance, and more. Toyota is aware of this problem and attempted to do a silent warranty extension. This is a safety hazard and all of the known vehicles affected should be recalled!

It’s been a year since I have owned my 2021Toyota Rav and it has randomly been shutting off with the notice: Power Steering Voltage Abnormality. I have taken the vehicle to get checked but nothing is coming up indicating what the issue is. The battery is fine, the alternator is fine, and there doesn’t seem to be any electrical issues with the power steering. I have seen that there has been certain recalls on the power steering voltage notice on the Toyota Ravs and owners complaining about a random shut off on their vehicles. I am one of those owners and would like to know why my vehicle hasn’t been issued a recall. It is a safety hazard and concern. My vehicle has been shutting off in the middle of a busy highway. Please look into this issue.

Hybrid system failure resulting in vehicle not being drivable at all. Failure is due to corrosion from connector between high voltage harness into rear traction motor. Failure occurred 8,000 miles past warrantee cut-off (100,000) and will require weeks to months to fix 2/2 parts on backorder.

Several malfunction warnings (pre-collision system malfunction, AWD malfunction, engine malfunction, parking brake malfunction) as well as several warning lights appeared on my dash. Took vehicle to a Toyota dealership for repairs. Fuel pump was replaced. Drove car a few days later and all the same warnings and lights came back on and this time the vehicle stalled in the middle of the road while driving. Was able to restart but had as soon as vehicle was stopped it would stall. Had to restart the vehicle several times while driving 2 miles just to get it home.

Dear NHTSA Office of Defects Investigation, I am writing to formally report a safety concern with my 2021 Toyota RAV4 XSE Hybrid regarding its fuel tank capacity and refueling issue. Despite the advertised fuel tank capacity of approximately 14.5 gallons, my vehicle only allows me to fill around 9 gallons before the pump automatically shuts off. This significantly reduces my driving range and forces me to refuel much more frequently than expected. After researching, I discovered that Toyota issued Technical Service Bulletin T-SB-0109-20 acknowledging this issue, along with Customer Support Program 20TE04. However, my local Toyota dealership refuses to acknowledge the issue or perform the necessary repairs, despite my vehicle clearly experiencing the problem. I believe this poses a safety risk because: •The incorrect fuel level readings can lead to drivers miscalculating available fuel, potentially resulting in unexpected stalls or breakdowns. •It suggests a defect in the fuel tank design,...

The contact owns a 2021 Toyota Rav4. The contact stated that while the vehicle was parked, being driven, or stationary, the climate control module turned off sporadically. There were no warning lights illuminated. The contact turned off the vehicle for half an hour and then restarted the vehicle, and the climate control module worked as needed for a month. The contact stated that the instrument panel was dim, and the numbers were difficult to see. The vehicle was repaired three times however, the failure persisted. The vehicle was then taken to a dealer, where it was diagnosed with a climate control module failure. The vehicle was not repaired after the recent failure. The contact had replaced the climate control module three times prior. The manufacturer was not made aware of the failure. The failure mileage was approximately 30,000.

Just a little over 33k miles, regular maintenance wit dealer, after the power steering light flashes on then goes off after auto stop of motor when stopping and stop at long intervals sometime see a battery charging at same time. Fluid is great no noise. I see a recall but not on this vin. However I’m reading on line several of these are having the same issue, the car is too new..

I've seen this error message (voltage abnormality steering power low) a few times whenever we are at a stop light and begin to go. This only happens whenever the Start/Stop function is active so the engine is stopped while not moving. Then once we start going, it will show up for a second and then disappear. We have taken the car to a local shop where they said that the alternator was beyond normal use and we received a quote as they believed it was worth replacing. When we went to Toyota dealership as the alternator is still under warranty they said they didn't see anything, they would not allow us to drive the car or hold onto the break in their shop. Problem continues to persist.

There is an issue that seems to be plaguing certain 2021+ Toyota models after a lot of research on this topic. My RAV4 has been operating perfectly and around 42k the Voltage Abnormality: Power Steering Low warning came on. I've had the alternator, starter, and battery tested. Alternator and starter were given a good bill of health, the battery was given a full recharge as it outputting a bit low. The battery was put back into my car and the issue still persists. The issue only occurs after the automatic shut off feature engages when fully stopped at a light or in traffic. If I drive with the feature turned off (something I have to do every time I turn the car on now) the issue doesn't happen. If the issue persists the car can become "locked" and either completely undriveable or a safety hazard to drive if the issue/warning...

Cruise control suddenly quit working, alarms for hybrid system malfunction, cruise control malfunction. This is a known issue for Toyota, high voltage leaking out because of a corroded ground. This repair is going to cost around $7,000 out of pocket.. My car is 3 years old.

We’ve had the car for three months had it to the shop of the Toyota place seven times for the electrical issue the car will shut off going down the road when you give a gas when you let off the gas, it will start back up spitting sputter, the instrument cluster The gauges will stick in one spot and not budge and you lose all power to the vehicle to drive

A warning message came up that the HYBRID SYSTEM MALFUNCTION contact dealer. This was confirmed by the dealer. According to the dealer and message boards at various web sites, the Hybrid System Malfunction is NOT uncommon. To fix the problem, a wire harness must be replaced with a replacement cost of $2000-$4000. When I asked what changes have been made to the replacement part to address the corrosion problem, the response was there might be a new coating but we do live in New Hampshire.

I received an error message “Engine stopped, steering power low” after driving an hour in the rain, sat in my car for about 20 mins with wipers on, engine began to jerk aggressively then shut off. I could not gas it or move the car. I let the car sit after being towed, it ran fine as if nothing happened. I got a battery test and it was at 100% charge according to Autozone. The check engine light, battery light and steering light came on. No prior indications of this problem.

The front passenger door started to "not unlock" when using the keys or door buttons to unlock it, you would have to manually unlock the passenger door by reaching across from the driver's side of the car. For about a week, that was happening, then that same door started to "not lock" using the key fob, handle or door buttons, so both locking and unlocking could only be done manually. Then the most concerning incident, while driving and while a passenger was seated in the front seat, upon rounding a corner (moving less than 20 mph) in a very busy town full of parked cars and pedestrians, the closed front passenger door flung open while the vehicle was turning and moving, almost striking a pedestrian and parked car. The passenger was able to safely close the door, but this would have been impossible had there only been a driver in...

When driving the car and stopping at a stop sign or stop light, the engine will shut off. The automatic restart occurs and with the headlights on the climate temp control display flickers While all the other dashlights remain bright. Many people are disabling the system. Since there is a switch you can press, defeating the system. Toyota sent a technical specialist who inspected the system. And since he couldn't find how to fix it, declared it normal. Apparently toyota designed the car to do this for some unknown reason. He stated That lights will dim when the car restarts. It is not dimming as if a current draw, it flickers every time. This of course, affects the fuel economy of the car, defeating the system, which many people do and creates a concern of why that one component flickers. Toyota installs a heavy 605A battery to operate this system...

The vehicle was left parked for 7 days and battery was found to have discharged and would not start or provide any displays on the dash board. No map lights were were found to have been left on and no accessories were connected.

I was in a bad car accident last Wednesday July 26, 2023 It was very scary and Bizarre; My car accelerated (started racing)and when I stepped on brake, it accelerated more. I saw a message flash up on my GPS screen but obviously couldn't read it as I was trying to stop my car. The Auto brakes didn’t work, I crashed into a tree; air bags didn’t deploy and I got this message ("CHECK ENGINE! A MALFUNCTION IN THE ELECTRONIC CONTROL OF THE ENGINE,THROTTLE, OR AUTOMATIC TRANSMISSION HAS BEEN DETECTED.CONTACT YOUR TOYOTA DEALER IN ORDER TO HAVE YOUR VEHICLE INSPECTED." (See attached). Luckily I was in an almost empty parking lot when this happened, if not i could have been killed or killed someone else. All the safety back ups failed. I took a picture of the message-will attach it to this report. I was taken to Huntington Hospital ER...

The contact rented a 2021 Toyota Rav4. The contact stated that while driving at an undisclosed speed, he heard a vibrating sound coming from the front driver’s side windshield. The vehicle was taken to an independent mechanic; however, the contact was informed that the vehicle was a rental and could not be diagnosed. The contact was informed to return the vehicle to Avis Car Rental. The contact stated that on a separate occasion, while driving at an undisclosed speed, the vehicle lost motive power and stalled. The contact stated that he was able to restart the vehicle after several minutes. The contact stated that due to the loss of motive power, the front driver’s and passenger’s side headlights failed to operate as needed. The vehicle was taken to the dealer however, the contact was informed that the vehicle could not be diagnosed since the vehicle was a rental. The vehicle...

We have water becoming stuck in our back passenger door due to a weather strip design flaw in Toyota Rav4 Hybrids. This will begin to happen to all weather strips and eventually destroy the interior and electrical if not repaired. This is a common design flaw in newer Toyota Rav4 Hybrids and we are lucky it's just our one door so far.  I've been informed (by our Toyota Tech) that eventually all of the doors and the roof will leak due to this Toyota design flaw.   When we took the car to get fixed at the dealership, they let us know it was an expensive repair, advised it was a design flaw, other customers are affected, and allowed us time to research before paying for the repair. We may attempt it ourselves since Toyota corporate has refused a reimbursement for the repair. This is a Toyota design flaw and requires...

We were on a drive back from Nashville like normal. My mom had picked me up from work at around 07:15. The car started making strange sounds as we were driving down the highway. It started yelling at us to pull over to a safe spot and slowing down. All of the lights had come on flashing at this time. It didn’t even make it to the shoulder; We made a stop on the triangle area for when cars come in from the exit. As soon as we stopped, smoke started engulfing us and 2 guys who saw this happening parked on the shoulder and came running out of their van with fire extinguishers and started telling us to get out. When we went around the car to check what was going on, we noticed the fire that had started from the bottom of it. They fired the extinguishers a...

I have a 2021 Rav4 gas LE. I bought it new in May 2021 and have 38,000 miles on it. I was casually driving the car going 30-40mph when the car dashboard lit up. The first notification I got was on the screen display saying a malfunction in the charging system was detected and to stop in a safe location. Next, all my dashboard lights turned on (tire pressure, traction control, check engine, ABS, brake, battery light, etc.) and got the following messages on the dashboard: - parking brake malfunction - pre collision malfunction - brake power low - stop in a safe place - secondary collision brake system malfunction - antilock brake system malfunction voltage ability - Voltage abnormality - steering power low And then finally, the “engine stopped” message when the emergency brakes engaged on their own while I was slowing down at a red light. Before this,...

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-Rear passenger door lock actuator fails -Safety risk of door not automatically locking when driving -Problem has been reproduced because it has occurred more than once -No inspection has taken place -No warning lamps or messages

Since I bought my brand-new car 1. the engine has stopped 5 times. 2. My windshield cracked. 3. There is low tire air pressure indicator that appears once in a while. A new battery was replaced, and it now cannot start. The message on the screen indicates: "IGNITION ON, Voltage abnormality steering power Low. Visit your Dealer." I took it the Dealer and now they are not able to find out what the problem is because I had to jam started the car for it to be towed.

I was parked at a store, engine off. Was in there 3 minutes and another customer ran inside and said a car was on fire, the employee asked if it was mine. I ran outside and it was indeed mine. The rear tail light was all melted and on fire, billowing smoke was coming out the sides of the hatch so I opened it quickly to get the fire out. The store employee put the fire out with his fire extinguisher. No prior warning lights were present when driving it before this occurred. The car is at Toyota dealer presently while they determine the cause.

The contact stated that the owner of a 2021 Toyota Rav4 was driving approximately 35 mph when the odor of burning rubber was present inside the cabin of the vehicle. After stopping and exiting the vehicle flames were present coming from the engine compartment. The fire department was called to the scene and extinguished the flames. The vehicle was destroyed during the incident. A fire report was taken at the scene and the vehicle was towed away. The cause of the failure was not determined. The manufacturer and local dealer were not notified. The contact indicated that the vehicle had recently been repaired after a front-end crash had occurred. The contact also references an NHTSA open investigation(PE21005) for the same failure that had occurred. The failure mileage was 30,000

In the driver's side, rear therr was smoke coming and before that occurred the lights flickered several times. There may have been steering issues before the rear fire and blinking likes as smoke started to show. The safety is due to fire risk. There is some media information on the same vehicle yet 2017 vehicle year that similar electrical issue occurred. The vehicle has not been inspected by anyone as it just occurred a few days ago. There were no warning lights or prior failures.

I had 2 sudden acceleration incidents. The first occurred 10/6/21.My car lurched forward & hit a pole. I was with my mom who saw me press the brake, which did not engage. My car has an auto-braking system which did not function as designed. I took it to Toyota.They determined there were no issues w/the vehicle. I insisted there was something wrong & warned this will happen again & could be much worse. I felt defeated but hoped it was an isolated glitch & hoped for the best. Fast forward 2 months to 12/13/21 I was in a drive-thru using the hold button, which is a feature that holds the brake in place, so my foot was not on any pedal. All of a sudden, my car began to accelerate & the brakes would not engage. An error message on the dash said “BRAKE MALFUNCTION”. I could not stop the...

To whom this may concern, I have had many problems with the Toyota Rav-4. I had so many problems with my 2017 Rav 4, that I under pressure upgraded to the 2021 LE version. I have had many problems with the breaks. I have brought it in (3) times to be serviced since I purchased it in March of 2021. The breaks are still squeaking. I have also had problems with the electrical system. The dash panel comes on, and abruptly shuts down when it feels like it. My wipers also come on intermittently. Every time I try and talk to Toyota about this they tell me there is nothing wrong. This same thing happens with the 2017, until my breaking mechanism stopped. I am looking for someone to look into this matter because these are dangerous conditions and unacceptable especially for new cars.

THERE IS A RATTLING SOUND COMING FROM THE DRIVER'S DOOR WHEN THE CAR IS STATIONARY AND THE DOOR IS SWUNG CLOSED. THE REARVIEW MIRROR OF THE DOOR HAS SIGNIFICANT SHAKING WHILE THE CAR IS IN MOTION, SO THIS IS A SAFETY HAZARD. THE SPEAKER IN THE DRIVER'S DOOR MAKES A STATIC OR CRACKLING SOUND WHEN MUSIC IS OFF.

VEHICLE BATTERY COMPLETELY DEAD AFTER ONLY 3 DAYS OF NOT BEING DRIVEN. VEHICLE WOULD NOT START AND COULD NOT BE JUMP STARTED. VEHICLE IS ONLY 2 MONTHS OLD. WIRELESS CHARGING DOES NOT CHARGE CONSISTENTLY. INTERMITTENT CONNECTION ONLY AND GETS VERY HOT. USB PHONE CONNECTION RANDOMLY DISCONNECTS AND RECONNECTS. OCCASIONALLY THE VOICE COMMAND PROMPT ON CENTER CONTROL IS ACTIVATED AND STAYS CONNECTED WHEN CONNECTING A PHONE THROUGH USB AND CANNOT EXIT TO SEE INFORMATION DISPLAY. REMOTE START FROM FOB WILL NOT WORK. LANE DEPARTURE SYSTEM TOO SENSITIVE AND TAKES OVER STEERING OF CAR CAUSING COUNTERSTEERING FROM DRIVER CONTROL.