Toyota Recalls Thousands of Hybrid Vehicles Due to Fire and Power Loss Risk

More than 55,000 Toyota Corolla Cross Hybrid and Toyota Camry Hybrid models are being recalled by Toyota Motor Engineering & Manufacturing due to a defect that could lead to a loss of motive power or a fire. The issue stems from a bolt within the hybrid inverter assembly that may have been improperly torqued during production.

The recall impacts approximately 3,761 units of the 2026 Toyota Corolla Cross Hybrid and 51,644 units of the 2025-2026 Toyota Camry Hybrid. These vehicles were manufactured between August 27, 2025, and November 25, 2025, for the Corolla Cross Hybrid and between August 26, 2025, and November 18, 2025, for the Camry Hybrid. Not all vehicles produced within these date ranges were necessarily sold in the U.S. The defect specifically affects vehicles equipped with certain inverter assemblies supplied by Denso Manufacturing Tennessee, Inc.

The improperly torqued bolt within the inverter assembly can lead to several potential problems. It could result in incomplete contact at the inverter terminal, or the bolt might loosen entirely within the assembly. Either of these scenarios can create an open circuit, triggering a warning lamp. In some instances, this could also lead to the simultaneous activation of limp mode or a complete loss of motive power while driving. A loss of power at higher speeds increases the risk of a crash. Furthermore, if the loose bolt causes a short circuit while the ignition is on, it could generate sufficient heat to cause thermal damage to nearby components and potentially lead to a vehicle fire.

Toyota became aware of the issue in early November 2025, when a field report indicated a vehicle was unable to start. An inspection revealed a loose bolt within the inverter assembly. Further investigation by the supplier identified additional assemblies with bolts exhibiting low torque. A review of production history by the supplier found that changes to machine settings during a specific period could have led to this low torque condition. Toyota and the supplier confirmed that the torque was low enough for the bolt to detach and fall within the assembly.

As of December 10, 2025, Toyota had received 34 field technical reports and 15 warranty claims in the U.S. that are believed to be related to this condition. Owners of affected vehicles will be notified by mail between January 30, 2026, and February 13, 2026. Toyota advises owners of affected vehicles to park their cars outside until the remedy is available, due to the potential fire risk. The repair remedy will be provided free of charge. Further details regarding the specific repair will be communicated to owners when available. Vehicle identification numbers (VINs) will become searchable to determine if a specific vehicle is affected at a later date.

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

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