Massive Recall Issued for Toyota, Lexus, and Subaru Electric Vehicles Due to Visibility Hazard

A significant recall impacting nearly 95,000 electric vehicles has been announced by Toyota Motor Engineering & Manufacturing, affecting select models of the 2023-2025 Subaru Solterra, 2023-2025 Lexus RZ, and 2023-2025 Toyota bZ4X. The recall addresses a defect in the Heating, Ventilation, and Air Conditioning (HVAC) system that can impair windshield defroster function, potentially reducing driver visibility in cold weather conditions and increasing the risk of a crash.

The issue stems from the programming of the HVAC control Electronic Control Unit (ECU) software. Under specific failure modes, such as an electrical compressor malfunction, the HVAC system may enter a failsafe mode that disables the heater and compromises the defroster’s ability to clear frost, ice, or fog from the windshield. This reduced defrosting performance is particularly concerning at lower temperatures, where ice and fog can accumulate more readily. The National Highway Traffic Safety Administration (NHTSA) has assigned this recall the number 25V577.

The potentially affected vehicles include 32,320 Subaru Solterra models manufactured between March 29, 2022, and June 3, 2025. Additionally, 20,501 Lexus RZ models produced from January 23, 2023, to June 12, 2025, are part of the recall. The largest group of affected vehicles consists of 41,499 Toyota bZ4X models, manufactured from March 30, 2022, to June 12, 2025. It is important to note that not all vehicles within these production ranges were sold in the U.S., and the defect specifically impacts vehicles equipped with a particular HVAC control ECU software from a specific supplier.

Owners of the affected Toyota and Lexus vehicles will be notified to bring their cars to a Toyota or Lexus dealership for a software update to the HVAC control ECU, which will be performed free of charge. For Subaru vehicles, retailers will also update the HVAC control ECU software at no cost to the customer. As an additional measure for customer satisfaction, dealerships will also inspect the electrical compressor and replace it if necessary, also at no charge. The manufacturer responsible for the HVAC control ECU is DENSO CORPORATION.

Owners who have already paid for repairs related to this issue prior to the recall campaign will be eligible for reimbursement according to Toyota’s General Reimbursement Plan. Subaru will also provide reimbursement for repairs under its general plan submitted in May 2024.

Notifications to distributors and dealers are scheduled to be sent out on September 4, 2025. Owners of the affected vehicles can expect to receive their recall notices between October 20, 2025, and November 3, 2025. The recall is being implemented in phases, and information regarding vehicle identification number (VIN) searchability will be made available.

Article by Mel Anara, based upon information from Toyota Motor Engineering & Manufacturing

---