Toyota Motor Engineering & Manufacturing (Toyota) is recalling ~94,000 2023-2025 model-year bZ4X, Lexus RZ, and Subaru Solterra SUVs. During certain Heating, Ventilation, and Air Conditioning system problems (HVAC), such as electrical compressor failure, the defroster and defogger system may become inoperative because of a software problem in the Denso supplied ECU software. Apparently, Transport Canada originally identified the safety hazard.
“The subject vehicles are equipped with Heating, Ventilation, and Air Conditioning (HVAC) systems that, among other things, control the windshield defroster function. Due to the programming of the HVAC control ECU software, under certain conditions, such as a specific failure mode of the electrical compressor, the HVAC system will enter a failsafe mode that suspends the heater operation of the system and affects defroster function. In some cases, when the vehicle is operated in certain low temperatures, the defrosting performance reduces and may not remove frost, ice, and/or fog from the windshield glass. This can reduce driver visibility and increase the risk of a crash in certain driving conditions,” Toyota said in the mandatory safety defect recall (49 CFR § 573) filing made public by the National Highway Traffic Safety Administration this morning.
Dealers will update the HVAC control ECU software, free of charge as mandated by U.S. safety regulations. Dealers will also inspect the electrical compressor, and replace it, if necessary, free of charge. Owner notification letters are not expected to be mailed until 20 October 2025. Owners may contact Toyota’s customer service at 1-800-331-4331. Toyota’s numbers for this recall are 25TB07 and 25TA07. Lexus’ numbers for this recall are 25LB04 and 25LA04. Subaru’s number for this recall is WRD-25.
Chronology
March, 2025 – August, 2025: “In March 2025, Toyota received an information request from Transport Canada (TC) regarding HVAC system failures on some 2023-2024 Toyota bZ4x vehicles. Upon review of the complaints received by TC, customers reported the defroster did not operate when the windshield fogged during driving and that the electrical compressor, which is an HVAC-related component, appeared to be a main failure component. The electrical compressor serves as one of two heat sources; even if one heat source fails, the other remains operational. Therefore, it was initially assumed that the impact on windshield fogging and defroster performance would be limited. To better understand the conditions under which the defroster was not functioning, customers were contacted, and a vehicle data investigation was initiated.
“Based on the customer contacts, it was found that they had been driving in extremely low temperature environments. Vehicle testing was conducted to simulate electric compressor failure occurrences under extreme cold conditions. Testing did not confirm fogging of the windshield during driving. However, heater performance was worse than expected, as electric compressor failure had a greater impact on heater performance than initially assumed. A review of the HVAC system control logic was then undertaken. After reviewing the HVAC control logic, it was found that, under certain conditions, such as certain electric compressor failures, the HVAC control ECU enters a fail-safe mode that also suspends the second heat source, which had been previously assumed to remain operational. Toyota hypothesized that this control logic could potentially affect heater and defrosting performance, and further vehicle tests were conducted.
“The testing confirmed that the defrosting performance reduces within a specific temperature range due to fail-safe mode operation. When an HVAC-related component failure occurs, such as a specific failure mode of the electric compressor, and the system enters fail safe mode, warning messages such as “EV System Malfunction” or “Drive Start Control Malfunction,” and warning indicators illuminate. Under these conditions, when the vehicle is operated in certain low temperatures, the defrosting performance reduces and may not remove frost, ice, and/or fog from the windshield glass. This can reduce driver visibility and increase the risk of a crash in certain driving conditions.”
August 29, 2025: “Based on the results of the above investigation, Toyota decided to conduct a voluntary safety recall campaign. As of August 22, 2025 based on a diligent review of records, Toyota’s best engineering judgment is that there are 31 Toyota Field Technical Reports and 501 warranty claims that have been received from U.S. sources that relate or may relate to this condition and which were considered in the decision to submit this report,” Toyota said in the filing.
Manufacturer’s Campaign Numbers:
- Toyota bZ4X : 25TB07 [Interim] / 25TA07 [Remedy]
- Lexus RZ : 25LB04 [Interim] / 25LA04 [Remedy]
- Subaru Solterra : WRD-25
About Ken Zino
Ken Zino, editor and publisher of AutoInformed, is a versatile auto industry participant with global experience spanning decades in print and broadcast journalism, as well as social media. He has automobile testing, marketing, public relations and communications experience. He is past president of The International Motor Press Assn, the Detroit Press Club, founding member and first President of the Automotive Press Assn. He is a member of APA, IMPA and the Midwest Automotive Press Assn.
He also brings an historical perspective while citing their contemporary relevance of the work of legendary auto writers such as Ken Purdy, Jim Dunne or Jerry Flint, or writers such as Red Smith, Mark Twain, Thomas Jefferson – all to bring perspective to a chaotic automotive universe.
Above all, decades after he first drove a car, Zino still revels in the sound of the exhaust as the throttle is blipped during a downshift and the driver’s rush that occurs when the entry, apex and exit points of a turn are smoothly and swiftly crossed. It’s the beginning of a perfect lap.
AutoInformed has an editorial philosophy that loves transportation machines of all kinds while promoting critical thinking about the future use of cars and trucks.
Zino builds AutoInformed from his background in automotive journalism starting at Hearst Publishing in New York City on Motor and MotorTech Magazines and car testing where he reviewed hundreds of vehicles in his decade-long stint as the Detroit Bureau Chief of Road & Track magazine. Zino has also worked in Europe, and Asia – now the largest automotive market in the world with China at its center.
Bad Defrosters – Toyota Motor Recalls Lexus and Subaru SUVs
Toyota Motor Engineering & Manufacturing (Toyota) is recalling ~94,000 2023-2025 model-year bZ4X, Lexus RZ, and Subaru Solterra SUVs. During certain Heating, Ventilation, and Air Conditioning system problems (HVAC), such as electrical compressor failure, the defroster and defogger system may become inoperative because of a software problem in the Denso supplied ECU software. Apparently, Transport Canada originally identified the safety hazard.
“The subject vehicles are equipped with Heating, Ventilation, and Air Conditioning (HVAC) systems that, among other things, control the windshield defroster function. Due to the programming of the HVAC control ECU software, under certain conditions, such as a specific failure mode of the electrical compressor, the HVAC system will enter a failsafe mode that suspends the heater operation of the system and affects defroster function. In some cases, when the vehicle is operated in certain low temperatures, the defrosting performance reduces and may not remove frost, ice, and/or fog from the windshield glass. This can reduce driver visibility and increase the risk of a crash in certain driving conditions,” Toyota said in the mandatory safety defect recall (49 CFR § 573) filing made public by the National Highway Traffic Safety Administration this morning.
Dealers will update the HVAC control ECU software, free of charge as mandated by U.S. safety regulations. Dealers will also inspect the electrical compressor, and replace it, if necessary, free of charge. Owner notification letters are not expected to be mailed until 20 October 2025. Owners may contact Toyota’s customer service at 1-800-331-4331. Toyota’s numbers for this recall are 25TB07 and 25TA07. Lexus’ numbers for this recall are 25LB04 and 25LA04. Subaru’s number for this recall is WRD-25.
Chronology
March, 2025 – August, 2025: “In March 2025, Toyota received an information request from Transport Canada (TC) regarding HVAC system failures on some 2023-2024 Toyota bZ4x vehicles. Upon review of the complaints received by TC, customers reported the defroster did not operate when the windshield fogged during driving and that the electrical compressor, which is an HVAC-related component, appeared to be a main failure component. The electrical compressor serves as one of two heat sources; even if one heat source fails, the other remains operational. Therefore, it was initially assumed that the impact on windshield fogging and defroster performance would be limited. To better understand the conditions under which the defroster was not functioning, customers were contacted, and a vehicle data investigation was initiated.
“Based on the customer contacts, it was found that they had been driving in extremely low temperature environments. Vehicle testing was conducted to simulate electric compressor failure occurrences under extreme cold conditions. Testing did not confirm fogging of the windshield during driving. However, heater performance was worse than expected, as electric compressor failure had a greater impact on heater performance than initially assumed. A review of the HVAC system control logic was then undertaken. After reviewing the HVAC control logic, it was found that, under certain conditions, such as certain electric compressor failures, the HVAC control ECU enters a fail-safe mode that also suspends the second heat source, which had been previously assumed to remain operational. Toyota hypothesized that this control logic could potentially affect heater and defrosting performance, and further vehicle tests were conducted.
“The testing confirmed that the defrosting performance reduces within a specific temperature range due to fail-safe mode operation. When an HVAC-related component failure occurs, such as a specific failure mode of the electric compressor, and the system enters fail safe mode, warning messages such as “EV System Malfunction” or “Drive Start Control Malfunction,” and warning indicators illuminate. Under these conditions, when the vehicle is operated in certain low temperatures, the defrosting performance reduces and may not remove frost, ice, and/or fog from the windshield glass. This can reduce driver visibility and increase the risk of a crash in certain driving conditions.”
August 29, 2025: “Based on the results of the above investigation, Toyota decided to conduct a voluntary safety recall campaign. As of August 22, 2025 based on a diligent review of records, Toyota’s best engineering judgment is that there are 31 Toyota Field Technical Reports and 501 warranty claims that have been received from U.S. sources that relate or may relate to this condition and which were considered in the decision to submit this report,” Toyota said in the filing.
Manufacturer’s Campaign Numbers:
About Ken Zino
Ken Zino, editor and publisher of AutoInformed, is a versatile auto industry participant with global experience spanning decades in print and broadcast journalism, as well as social media. He has automobile testing, marketing, public relations and communications experience. He is past president of The International Motor Press Assn, the Detroit Press Club, founding member and first President of the Automotive Press Assn. He is a member of APA, IMPA and the Midwest Automotive Press Assn. He also brings an historical perspective while citing their contemporary relevance of the work of legendary auto writers such as Ken Purdy, Jim Dunne or Jerry Flint, or writers such as Red Smith, Mark Twain, Thomas Jefferson – all to bring perspective to a chaotic automotive universe. Above all, decades after he first drove a car, Zino still revels in the sound of the exhaust as the throttle is blipped during a downshift and the driver’s rush that occurs when the entry, apex and exit points of a turn are smoothly and swiftly crossed. It’s the beginning of a perfect lap. AutoInformed has an editorial philosophy that loves transportation machines of all kinds while promoting critical thinking about the future use of cars and trucks. Zino builds AutoInformed from his background in automotive journalism starting at Hearst Publishing in New York City on Motor and MotorTech Magazines and car testing where he reviewed hundreds of vehicles in his decade-long stint as the Detroit Bureau Chief of Road & Track magazine. Zino has also worked in Europe, and Asia – now the largest automotive market in the world with China at its center.