Steering Loss – Toyota Recalls Corolla and Corolla Hybrids

Toyota Motor Engineering & Manufacturing is recalling 8057 model year 2023-2024 Corolla and Corolla Hybrid vehicles for the loss of steering control, according to documents made public today by the National Highway Traffic Safety Administration.

“Due to cracks developed during the manufacturing process, the steering intermediate shaft assembly may fracture and possibly result in the shaft detaching from the steering column,” Toyota told NHTSA in the required safety defect recall filing.

“The steering system of the subject vehicles consists of a steering intermediate shaft assembly, which connects the steering wheel to the steering rack. There is a possibility that the upper universal joint on the steering intermediate shaft assembly may have developed cracks during the manufacturing process at a supplier. During use, the cracks may grow over time due to stress created by steering inputs. If the cracks grow sufficiently, this can lead to abnormal noise, abnormal steering vibration, and additional play in the steering wheel while turning. Eventually, the universal joint can separate. If the vehicle is in motion, this may cause a loss of steering control and an increased risk of a crash,” Toyota said.

Chronology

• In October 2023. Toyota received information from the supplier indicating that there was a possibility steering intermediate shafts may have been manufactured with cracks on the U-shape portion of the upper universal joint. The supplier quarantined all inventory that was manufactured with the same production process. The supplier inspected approximately 140,000 parts that were quarantined and found cracks in 20 parts.
• The supplier analyzed the 20 parts with cracks to determine which parts had the largest cracks. The supplier conducted durability bench testing on 9 parts, which had the largest cracks. As a result, 1 part did not meet the durability requirements of the design specification. Based on the above tests, Toyota concluded that the possibility that a steering intermediate shaft was distributed into the market with cracks that could lead to breakage during vehicle use was extremely low.
• January 2024 – October 2024. Toyota and the supplier investigated the forging process and found that the possibility of crack occurrence increased if the difference in the friction coefficient between the inside surface and outside surface of the U-shape was larger during pressing.
• Based on the above findings, the supplier identified that the amount of lubricant applied to the work-piece before forging was reduced during a specific period due to a specific spraying condition, and this was a factor that could increase the friction coefficient during forging. In addition, there was production history that showed the forging facility experienced stoppages during the same period. The supplier determined that forging facility stoppages could cause the workpiece to be left for long periods of time, further reducing the amount of lubricant and increasing the friction coefficient during forging. When performing a reproduction test with these two production conditions, the supplier reproduced the crack occurrence in the U-shape portion of the upper shaft.
• Early November 2024. From the above investigation results, the supplier was able to revise the production period in which shafts with cracks might have been produced. The supplier determined that approximately 4,700 parts that were manufactured during this period were a part of the original quarantined population, including the 1 shaft that did not meet design specification during durability testing. Based on this new production information, Toyota revised its calculation of intermediate shafts with cracks that could lead to breakage during vehicle use that may have been distributed in the market.
• November 15, 2024. Based on the results of the investigation, Toyota decided to conduct a voluntary safety recall campaign. As of November 14, 2024, based on a diligent review of records, Toyota’s best engineering judgment is that there are no Toyota Field Technical Reports and no warranty claim 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
• Notifications to owners of the affected vehicles will occur by 20 January 2025. All known owners of the subject vehicles will be notified to return their vehicles to a Toyota dealer. For all involved vehicles, the dealer will replace the intermediate shaft with a new one, free of charge. As the owner notification letters will be mailed out well within the active period of the Toyota New Vehicle Limited Warranty (“Warranty”), all involved vehicle owners for this recall would have been provided a repair at no cost under Toyota’s Warranty.

Dealers will replace the intermediate steering shaft, free of charge as required by U.S. Federal Safety regulations. Owner notification letters are not expected to be mailed until 20 January 2025. Owners may contact Toyota customer service at 1-800-331-4331. Toyota’s number for this recall is 24TB13/24TA13. Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 or go to nhtsa.gov about NHTSA recall 24V878.