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Toyota RAV4 Prime Recall 23V478: Plug-in hybrid DC-DC converter may short and cause fire

NHTSA campaign 23V478, reported July 12, 2023, 43,442 vehicles potentially affected.

What this recall means for you

A component in the DC-DC converter, the unit that steps down high-voltage battery power for the vehicle's low-voltage systems, may have been damaged during production. The damage can cause an electrical short circuit inside the converter.

A short circuit can make the DC-DC converter overheat, which raises the risk of a vehicle fire. Until the repair is done, owners are advised not to charge the vehicle when the outside air temperature is below or expected to drop below 41 degrees Fahrenheit (5 degrees Celsius).

The DC-DC converter will be replaced free of charge at an authorized dealer. Owners can call Toyota customer service at 1-800-331-4331 with questions; Toyota's recall numbers are 23TB07 and 23LB01. Owner notification letters were mailed December 29, 2023. You can also check your vehicle identification number (VIN) for open recalls.

Check whether this recall is open on your vehicle

The repair is normally free at an authorized dealer.

Official recall notice

Safety recall 23V478Toyota Motor Engineering & Manufacturing
Component
ELECTRICAL SYSTEM:PROPULSION SYSTEM:DC/DC CONVERTER
Problem
Toyota Motor Engineering & Manufacturing (Toyota) is recalling certain 2021-2022 RAV4 Prime and 2022 Lexus NX450h+ plug-in hybrid electric (PHEV) vehicles. The electric current rectifying module contained within the DC-DC converter may have been damaged during production, which can result in an electrical short-circuit.
Risk
A short circuit can cause the DC-DC converter to overheat, increasing the risk of a vehicle fire.
Remedy
Owners are advised not to charge their vehicles when the ambient air temperature is below or expected to drop below 41 degrees Fahrenheit (5 degrees Celsius). Dealers will replace the DC-DC converter, free of charge. Owner notification letters were mailed December 29, 2023. Owners may contact Toyota's customer service at 1-800-331-4331. Toyota's number for this recall is 23TB07/23LB01.
Notes
Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.nhtsa.gov.

Affected vehicles

Lexus NX450H+2022
Toyota RAV4 Prime20212022