Automaker identified problem in supplier production line in Tennessee; Repair involves tightening or changing the inverter module.
Toyota announced a recall involving about 55 hybrid vehicles in the United States due to a failure in the assembly of electrical components. The problem, originating in a poorly tightened bolt during the manufacturing process, exposed a vulnerability in the models’ high-voltage system, with risks ranging from loss of propulsion to the possibility of fire.
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The technical defect is located in the inverter, the device responsible for managing the flow of energy between the high-voltage battery and the electric traction motor. According to the automaker’s report, a bolt that secures a terminal inside the inverter may not have been tightened to the specified torque at supplier Denso’s plant in Tennessee.
With the natural vibration of the vehicle, this loose connection can come loose, causing poor contact. In technical terms, this creates the risk of arc flash and excessive overheating. In practice, the driver of the Camry or Corolla Cross may notice warning lights on the dashboard, followed by a loss of power from the drive wheels. In extreme cases, overheating of the terminal can start a fire in the engine compartment.
The recall specifically affects the 2025 lineup of two of the brand’s flagship products. The largest volume involves the Camry Hybrid sedan, with approximately 51,600 units committed. The Corolla Cross Hybrid SUV was also hit, adding about 3,760 units to the list.
Toyota acted after identifying field reports, mentioning almost 50 technical notifications related to the defect, although there is no record of accidents or injuries so far. The correction will be carried out at the brand’s dealerships free of charge: technicians inspect the inverter’s serial code and, if the batch is affected, perform the correct tightening of the screw or the complete replacement of the inverter set, ensuring the integrity of the electrical system.
