Toyota's Prius Brake Malfunction Crisis; More Problems

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Toyota Admits Design Flaw With Prius Brakes


Toyota Motor Corp. acknowledged design problems with the brakes in its prized Prius hours before the U.S. Department of Transportation opened an investigation into the 2010 model.

The new investigation adds to the catalog of woes for the Japanese automaker as it reels from massive gas-pedal recalls around the world.

The National Highway Traffic Safety Administration told the AP it received 124 reports from consumers, including four reports of crashes. The investigation will look into allegations of momentary loss of braking capability while traveling over uneven road surfaces, potholes or bumps.

The Japanese government has ordered Toyota to investigate brake problems. The automaker said it had corrected problems with the antilock brake system in Prius models sold since late last month, including those shipped overseas.

But the company said it was still investigating how to inform customers who had bought them earlier. Nothing was decided on that front for Prius gas-electric hybrids sold outside Japan, according to Toyota.

"We are investigating whether there are defects in the Prius," Toyota executive Hiroyuki Yokoyama told reporters at the automaker's Tokyo headquarters.

When the car moves on a bumpy or slippery surface, a driver can feel a pause in the braking when the vehicle switches between the traditional hydraulic brakes and the electronically operated braking system, said Paul Nolasco, a company spokesman. He credited that pause to the two systems in a gas-electric hybrid — the gas-engine and the electric motor.

The brakes start to work if the driver keeps pushing the pedal, but the driver may momentarily feel they aren't working, he said. Fixing that included a software programming change, he said.

Company mulling Prius recall

Whether a recall was in the works for the Prius is still undecided, according to Toyota.

A major Toyota dealership in Tokyo said the automaker had informed dealers that Prius brakes can sometimes fail to work for less than a second but it had not told owners.

"It is disappointing because the Prius was receiving such rave reviews," said Hiroyuki Naito, a manager at the dealership. The latest model Prius hit showrooms last May and is only made in Japan.

In recent weeks, the automaker had answered questions about its overseas recalls for gas pedals with assurances that problems didn't extend to Japanese vehicles, implying it was doing a better job with quality control in Japan.

"I plan to drive very carefully"

But Prius owners were worried.

Akira Suzuki, 25, who makes surf boards and teaches surfing, was excited about the high mileage his recently purchased hybrid offers — but concerned about its possible problems.

"I'm not sure how safe it is. I plan to drive very carefully," said Suzuki, who lives in a Tokyo suburb.

Earlier in Washington, U.S. Transportation Secretary Ray LaHood startled the public with a comment, which he later retracted, that Americans should park their recalled Toyotas unless driving to dealers for accelerator repairs.

The Prius was not part of the recall spanning the U.S., Europe and China over sticking gas pedals in eight top-selling models including the Camry. That recall involved 2.3 million cars in the U.S. alone.

Toyota senior managing director Takahiko Ijichi defended the automaker's quality standards.

"We have not sacrificed the quality for the sake of saving costs," he said. "Quality is our lifeline. We want our customers to feel safe and regain their trust as soon as possible."

Toyota for the first time gave an estimate of the costs of the global gas-pedal recall. The $2 billion total represents $1.1 billion for repairs and $770 million to $880 million in lost sales.

Toyota is expecting to lose 100,000 in vehicle sales because of the recall fallout — 80,000 of them in North America.

The tarnishing of the Prius nameplate is also a serious setback for Toyota's recovery from the global auto slump.

"It's very unclear what the future will bring," said Mamoru Katou, auto analyst with Tokai Tokyo Research. "Toyota's image as a leader in hybrids has been hurt."

The automaker has received 77 complaints in Japan about braking problems for the Prius. Separately, the Japanese government confirmed 14 complaints. About 100 complaints over Prius brakes have been filed in the U.S.

At least one accident has been reported in Japan suspected of being linked to faulty braking. In that accident, in July 2009, a Prius crashed head on into another car, slightly injuring two people, according to the transport ministry.

Toyota had looked into that accident and concluded there were no problems with the Prius.

Dealers start receiving parts

In the U.S., harried dealers began receiving parts to repair defective gas pedals in millions of vehicles and said they'd be extending their hours deep into the night to try and catch up. Toyota said that would solve the problem — which it said was extremely rare — of cars unaccountably accelerating.

Toyota is set to face additional questioning from U.S. congressional and other government investigators. Toyota has shut down several new vehicle assembly lines and is rushing parts to dealers to fix problems with the accelerators, trying to preserve a reputation of building safe, durable vehicles.

The latest recall involves 2009-10 RAV4 crossovers, 2009-10 Corollas, 2009-10 Matrix hatchbacks, 2005-10 Avalons, 2007-10 Camrys, 2010 Highlander crossovers, 2007-10 Tundra pickups and 2008-10 Sequoia SUVs.

U.S. lawmakers who are now digging into the recalls say they would look into the Prius.

Many consumer groups have questioned whether Toyota's gas pedal fix will work and have asserted it could be connected to problems with the electronic throttle control systems.

Yasuaki Iwamoto, auto analyst with Okasan Securities in Tokyo, said the big challenge for Toyota was rebuilding its damaged brand, especially in overseas markets.

"For all people who own Toyota cars, for all people with jobs related to Toyota, this huge sense of uncertainty simply isn't going away," he said.



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Sources: MSNBC, Toyota, Google Maps

Toyota's Sticky Gas Pedals Conspiracy Or Poor Manufacturing?

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Toyota Extends Recall To China, Europe


Toyota Motor Corp. said Thursday it's closing in on solutions to a gas pedal system problem, but it still had no details on when drivers would see repairs as an embarrassing recall spread to more than 2.4 million vehicles on three continents.

Toyota dealers in the U.S. have been swamped with calls from concerned owners but had few answers as the recalls snowballed. Elkhart, Ind.-based CTS Corp., which made the parts, is cranking out redesigned gas pedal assemblies that fix the problem, which is caused by condensation around an arm attached to the pedal and springs that send the pedal back to the idle position.

Toyota engineers are developing ways to repair the pedal systems in existing cars and trucks, said spokesman Brian Lyons.

No decision has been made yet on whether to repair the pedals or replace them altogether, he said, and he would not estimate how long it will take for customers to see action. Lyons says the automaker has not decided if the new pedals will go first to factories so production of eight models can resume or to dealers for modification of new cars on their lots and cars being driven by their customers.

Toyota on Thursday extended its recalls to China and Europe, deepening the massive recalls that threatened to undermine the reputation of the world's top automaker as a manufacturer of safe, durable vehicles.

The automaker has informed Chinese authorities it will start a recall in February for 75,500 RAV4 vehicles that were manufactured in China between March 2009 and January 2010, said Toyota spokeswoman Ririko Takeuchi. Toyota is still unsure how many vehicles could have the defect in Europe.

House lawmakers, meanwhile, said they intend to hold a Feb. 25 hearing to review the complaints of sudden unintended acceleration in Toyota vehicles. "Like many consumers, I am concerned by the seriousness and scope of Toyota's recent recall announcements," said House Energy and Commerce Committee Chairman Henry Waxman, D-Calif.

Earlier this week, the company said it was suspending U.S. sales and production of eight models — including the Camry, America's top-selling car — to fix faulty pedal systems that could stick and cause acceleration without warning. A week before the sales suspension, Toyota had issued a U.S. recall for the same eight models, affecting 2.3 million vehicles, even before the recalls in China and Europe.

Also this week, Toyota announced the recall of 1.09 million vehicles in the United States over concerns that floor mats could bend across gas pedals, causing sudden acceleration. That recall covered five models — 2008-2010 Highlander, 2009-2010 Corolla, 2009-2010 Venza, 2009-2010 Matrix, and 2009-2010 Pontiac Vibe, a General Motors Corp. vehicle that shares parts with the Matrix. Those were in addition 4.2 million vehicles recalled in late 2009 over floor mat concerns. Some of the models in both recalls overlap.

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CTS also makes pedals for Honda Motor Co., Mitsubishi Motors, Nissan Motor Co. and Ford Motor Co. in China, but the company said pedals made for those manufacturers don't have the same design. Still, Ford on Thursday halted production of some full-sized commercial vehicles in China because they contain CTS gas pedals.

CTS officials say they have ramped up production at three factories to manufacture redesigned pedals. The pedals are meant to solve problems with condensation that Toyota has said can cause them to react slowly when a driver presses on the gas. In rare cases, the gas pedals can get stuck.

CTS says it is also working with the Japanese automaker to find a potentially quicker repair for vehicles already on the road.

Lyons says the company's No. 1 priority is figuring out how to repair the largest number of vehicles in the shortest amount of time.

Repairs to the pedals still have to go through the normal durability testing to make sure they work properly, Lyons said. He would not estimate how long it will take for Toyota to decide on repairing versus replacement, nor would he say how long it will be until cars and trucks are fixed.

Toyota officials met Thursday with the National Highway Traffic Safety Administration to discuss a potential fix for the recalled vehicles, according to a person who was briefed on the meeting. The person, who was not authorized to speak publicly about the private meeting, said NHTSA officials discussed the potential remedy with Toyota and the government said they would express any concerns they may have about the proposed fix.

The automaker does not need NHTSA's specific approval but company officials do not want to proceed with a fix if the government has concerns about it. NHTSA has not signed off on any fixes at this point, the person said.

Since the initial recall last October, the company has held discussions with the government over the accelerator problem, and NHTSA was expected to review a possible remedy for the latest recall.

The sales suspension in the U.S. — Toyota's biggest market — could endanger the company's fledgling earnings recovery. Toyota only returned to the black for the July-September quarter with net income of 21.8 billion yen ($241 million) after three straight losing quarters.

"It is still uncertain how this recall problem will affect Toyota's profits. But investors are worried it could really pressure the company's overall earnings," said Masatoshi Sato, market analyst at Mizuho Investors Securities Co. Ltd.

Fitch Ratings warned Thursday the massive recalls and sales suspension could dent Toyota's recovery, especially in the vital U.S. market.

Fitch placed Toyota's credit rating of 'A+' on watch negative, meaning the rating could be downgraded. That could increase the interest rate Toyota pays on any debt.

"The recalls and sales and production suspension cast a negative light on Toyota's reputation for quality, just as the company emerges from an unprecedented downturn in the auto industry," Fitch said in a statement.

In March of 2007, Toyota started getting reports of gas pedals being slow to rise after being depressed for acceleration. Engineers fixed the problem in the Tundra pickup early in 2008.

But troubles persisted in other models, eventually leading to last week's U.S. recall and the plans to suspend sales and shut down of six factories while Toyota tries to fix the problems.


Sources: MSNBC, Toyota