What 266 owners told NHTSA about the 2012 Toyota RAV4 Plug-in Hybrid

My 2012 Toyota RAV4 (Super White / Blizzard Pearl paint) is experiencing severe and recurring paint peeling caused by a known manufacturing defect in which the factory paint primer failed to properly adhere to the base metal layer. The peeling first began in 2023 following freezing weather in Austin, TX. It occurred again in 2024 after another freeze event, and then once more in 2025, at which point a large section of roof paint peeled off completely, exposing bare metal. I attempted to repair the damage with spray paint but the new paint continues to peel off as well, because the underlying adhesion defect was never corrected. This confirms the failure is rooted in the original factory primer, not in external damage or neglect. This poses a direct safety hazard to other drivers and pedestrians when paint debris becomes airborne at highway speeds, and the exposed bare metal is now vulnerable to rust and further structural deterioration. Toyota formally acknowledged this defect and created Customer Support Program ZKG to address it across nearly 1.74 million vehicles, including the RAV4. In July 2022, Toyota confirmed in writing that 'sunlight/ultraviolet exposure over time degrades the adhesion between the factory-applied paint primer coat layer and the base metal electrodeposition layer, causing paint to peel from the metal body panel.' Freeze-thaw cycles accelerate this exact failure mode by forcing moisture under already-weakened paint edges, causing rapid and widespread delamination — consistent with what I experienced after the 2023, 2024, and 2025 Austin winter weather events. I was not properly notified about Program ZKG and missed the coverage window as a result. Toyota has declined to provide goodwill assistance. Given that Toyota knowingly sold vehicles with a defective paint system, failed to adequately notify all affected owners, and that the ongoing peeling creates an active road safety hazard with bare metal now exposed on the roof, please investigate.

NHTSA ODI 11744656

My vehicle is a 2012 rav 4 sport, color Barcelona Red. Said color and model has been know to have clear coat and paint issues. My vehicles clear coat and paint in the top has been peeling at an alarming rate, a year or so ago it started, but the last 6 months have been excrutiating. This problem poses a risk to me as if the issue continues on, oxidation might occur and possibly lead to holes in the surface. To other paint flying off from the vehicle might distract them in the porcess of driving and the glare produces by it might impact others vision. Other areas that have been affected include, hood and side mirrors.

NHTSA ODI 11735644

LACK OF TIE POINTS: This is an issue with our RAV4, but it is an issue with about every vehicle manufactured recently. It is a requirement of drivers to “secure their load” but when top carrying boats it is very difficult to find suitable tie points in the front and rear of the vehicle. Could vehicle manufacturers be required to provide tie points suitable for securing loads? It could be as simple as providing smooth- edged holes in the chassis under both bumpers.

NHTSA ODI 11426354

PAINT IS PEELING ON MULTIPLE PANELS. THIS VEHICLE HAS NEVER HAD BODY DAMAGE OR BEEN INVOLVED IN AN ACCIDENT.

NHTSA ODI 11355343

PURCHASE NEW OFF LOT. VEHICLE BARELY USED. 2012 ONLY HAS SLIGHTLY OVER 26,000 ORIGINAL MILES. KEPT COVERED WHEN NOT IN USE. PAINT IS JUST POPPING ON IN SEVERAL LOCATIONS RIGHT DOWN TO THE PRIMER LAYER. STARTED NEAR BACK WINDOW, THEN WHEEL WELL AREA, ROOF SPOTS. WE HAVE PUT TOUCH UP PAINT ON THE BACK WINDOW THINKING WE COULD SLOW THE PROCESS BUT IT KEEPS GETTING BIGGER. NO ONE SEEMS TO HAVE AN ANSWER OTHER THAN THERE ARE A LOT OF COMPLAINTS FOR THE SAME ISSUE. ALL WILLING TO GIVE ESTIMATES FOR ME TO PAY FOR IT. OBVIOUSLY IT IS A PROBLEM THAT TOYOTA SHOULD BE PAYING FOR!!!!! THIS VEHICLE WAS TO BE MY LAST ONE AT MY AGE. I NEED ANSWERS

NHTSA ODI 11230981

THE WHITE PAINT IS PEELING OFF OF THE CAR IN MANY LOCATIONS INCLUDING THE ROOF, HOOD, BUMPERS, AND DOORS. THERE IS NO RUST PRESENT NOR WAS THE CAR DAMAGED IN ANY WAY. THE PAINT IS SIMPLY BUBBLING AND PEELING OFF. THE CAR HAS BEEN GARAGED THE MAJORITY OF ITS LIFE.

NHTSA ODI 11181575

RUST UNDER HOOD

NHTSA ODI 11181051

9/21/15 TN ACCIDENT REPORTED CASE #WC1523557 VECHILE TOWED, 04/05/216, AUTO AUCTION AUCTION ANNOUNCED AS TRUE MILEAGE UNKNOWN 901-480-4250 JUNE 7, 2018, PURCHASED FROM CARLOCK TOYOTA TUPELO, MS. AUTO CHECK REPORTED MULTIPLE OWNERS, , SCORE 68. DEALESHIP DID NOT REVEAL ANY OF THIS WHEN PURCHASED--ONLY FOUND OUT WHEN DIRECT GENERAL CANCELED POLICY BECAUSE OF AUTO CONDITION---DEALERSHIP ONLY USES CARFAX--FRONT BUMPER LOOSE AND CRINKLED, HOOD CRINKLED, BRAKES WERE NOT NEW AS WAS TOLD-A COVER UNDER HOOD MISSING WHICH COULD CAUSE A FIRE.

NHTSA ODI 11130005

CLOSED SUNROOF EXPLODED WHILE DRIVING ON HIGHWAY.

NHTSA ODI 11073615

DRIVER SIDE REAR QUARTER PANEL STARTED ON FIRE. THIS OCCURRED AFTER AN APPROXIMATELY 4 MILE DRIVE. I BELIEVE THE FIRE STARTED ON THE DRIVE. I PARKED THE VEHICLE IN A PARKING LOT WITH ONLY ONE OTHER VEHICLE. WHEN I WAS WALKING INTO THE STORE I SMELLED BURNING PLASTIC BUT DID NOT RELATE IT TO MY CAR BURNING. I WAS IN THE STORE ABOUT 5 MINUTES. WHEN I WALKED OUT I SAW THE FIRE. THERE WAS NO OUTSIDE INFLUENCE TO THE FIRE AND NOTHING INSIDE THE VEHICLE VEHICLE. THE ONLY THING IN THAT AREA OF THE VEHICLE IS WIRING.

NHTSA ODI 10958384

ON OCTOBER 17 SHORTLY BEFORE 2 PM PST IN CLEAR WEATHER, I WAS PULLING INTO A PARKING SPOT ON PRIVATE PROPERTY AT ABOUT 2 TO 3 MPH. I TURNED THE VEHICLE INTO THE SPOT AND APPLIED THE BRAKES BUT THE CAR SURGED OVER THE CURB, HIT A TREE, WENT OVER AN EMBANKMENT AND CRASHED ONTO A PARKED CAR. (THE AIRBAG DID NOT DEPLOY, BUT THERE WERE NO INJURIES.) THE IGNITION WOULD NOT TURN OFF AFTER REPEATED ATTEMPTS. FINALLY I DEPRESSED THE IGNITION BUTTON FOR ABOUT 10 SECONDS AND IT TURNED OFF. JUST 5 DAYS EARLIER, THE CAR HAD UNDERGONE A SAFETY RECALL REPAIR TO THE ELECTRONIC CIRCUITRY. TOYOTA HAD ISSUED A SAFETY RECALL DUE TO A SOFTWARE DEFECT WHICH AFFECTED "COMPONENTS IN THE ELECTRIC VEHICLE TRACTION MOTOR ASSEMBLY." WE INFORMED TOYOTA THIS APPEARED TO BE AN UNINTENDED ACCELERATION INCIDENT. THEY PROMISED TO ASSIGN AN ENGINEER TO THOROUGHLY INSPECT THE VEHICLE AND DOWNLOAD INFORMATION FROM THE EVENT DATA RECORDER (EDR). THE ENGINEER INSPECTED THE CAR AND PREPARED A 22 PAGE REPORT. HOWEVER HE WAS UNABLE TO DOWNLOAD THE EDR INFORMATION DUE TO A DATA COMMUNICATION ERROR. TOYOTA CLAIMED IT WAS DUE TO A LOW BATTERY. THE ENGINEER CONFIRMED TO ME THAT IT WAS A DATA COMMUNICATION ERROR AND THAT THE VEHICLE WAS HALF CHARGED WHEN HE DROVE IT. TOYOTA REFUSED TO SHARE THE ENGINEER'S REPORT. THEY STATED IN SIX SHORT SENTENCES THAT THE ACCELERATION AND BRAKE PEDALS BOTH WORKED. THEY DID NOT ADDRESS THE RECALL, THE INCIDENT WITH THE IGNITION SWITCH, OR THE DATA COMMUNICATION ERROR, ALL OF WHICH SIGNAL POSSIBLE PROBLEMS WITH THE ELECTRIC CIRCUITRY/SOFTWARE. WHEN WE WROTE THEM A DETAILED LETTER WITH ALL THE ATTACHMENTS TO DOCUMENT THE RECALL, THEY SIMPLY RESPONDED THAT THE ACCELERATION PEDAL AND BRAKE PEDAL WORKED.

NHTSA ODI 10811744

DRIVER DOOR AN D WINDOW AND COORDINATED LOCK ARE OUT OF SYNC: DRIVE ABOUT 1 MILE AND LOCK CLOSES LIKE SOUND OF BULLET. HAD BEGUN ABOUT 6 MOS. FOLLOWING PURCHASE (AUG, 2012). TAKING TO DEALER TOMORROW & LEAVING CAR UNTIL PROPERLY REPAIRED! THIS IS A TOYOTA RAV4 (2012), PURCHASED NEW. *TR

NHTSA ODI 10652824

I WAS PULLING INTO A PARKING PLACE AT OUR CHURCH. WHEN I TURNED INTO THE PARKING PLACE THE CAR TOOK OFF AND IT JUMPED AN 8 INCH CURBING AND RAN INTO THE PARISH CENTER WALL. IT TRIED TO CLIMB THE WALL. I PUSH THE ACCELERATOR TO TURN INTO THE PARKING SPACE AND THE CAR TOOK OFF! IT WAS NOT DRIVER ERROR! *TR

NHTSA ODI 10650934

I DRIVE A TOYOTA RAV4 V6 LTD, 2012 PURCHASED ON JAN 2, 2013. PRIOR TO THAT WE HAD A TOYOTA CAMRY 1999 WITH MORE 200K MILES ON IT. ON JULY 24TH, 2013, I WAS DRIVING AT A SPEED OF 10 MPH INSIDE THE APARTMENT COMPLEX AND WAS TURNING RIGHT TO PARK. I WAS ALMOST PARKED WHEN ALL OF A SUDDEN THE CAR SURGED AND ZOOMED OVER PARKING STOPPER, BREAKING OVERHEAD STORAGE BIN, ZOOMED AHEAD AND BANGED INTO THE BUILDING STAIRS. I KEPT PUMPING THE BRAKE ALL THROUGH, BUT THE CAR DIDNT STOP UNTIL IT HIT ON TO THE STAIRS OF APARTMENT. THE WHEELS WERE STILL ROLLING BUT IT COULDN'T GO AHEAD BECAUSE OF THE HEAVY STAIRS AND FINALLY AFTER CONTINUOUSLY STEPPING ON THE BRAKE IT STOPPED. MY RIGHT FOOT WAS ALL ALONG ON THE BRAKE AS IT ALWAYS IS WHEN I'M PARKING. BODY OF THE CAR WAS SEVERELY DAMAGED WITH GLASS PIECES ALL OVER ME. LUCKILY MY 3 YEAR OLD WAS SAFER AT BACK IN HER CAR SEAT. THE AIRBAGS DID NOT DEPLOY ON IMPACT. I'M HAVING MORE THAN 10 YEARS OF DRIVING EXPERIENCE AND IT WAS THE FIRST TIME THAT I WAS INVOLVED IN AN ACCIDENT. SINCE I'M A WOMAN EVERYONE WAS QUICK TO CONCLUDE THAT, I HAD STEPPED ON THE GAS PEDAL INSTEAD OF BRAKE. BUT I KNOW MY FOOT WAS ALL ALONG ON THE BRAKE, UNTIL THE CAR FINALLY STOPPED. THIS HAS CAUSED A LOT OF DAMAGE, ALTHOUGH I HAD INSURANCE TO COVER THE CAR, THE VALUE IS ZILCH NOW. THE CAR WAS NOT TOTALED AND REPAIRS WAS WORTH MORE THAN 20K. DRIVING THE CAR NOW, DOESN'T FEEL THE SAME AS THE COLLISION CENTER DID A CRAPPY REPAIR JOB. NOW THE CAR MAKES SOUNDS WHILE DRIVING, AS THOUGH IT WILL COME APART. WE ARE LEFT WITH NO OPTIONS OTHER THAN JUST TO DRIVE THE SAME CAR BECAUSE WE CAN'T AFFORD ANOTHER CAR. AFTER NOTIFYING TOYOTA AND AFTER NUMEROUS CALLS THEY COLLECTED THE EDR AND SENT US A REPORT STATING THAT NOTHING WAS WRONG WITH THE VEHICLE. IT WAS OUR FAULT THAT WE DIDN'T REALIZE TOYOTA HAD ISSUES RELATED TO UNINTENDED ACCELERATION PRIOR TO BUYING THE RAV4. *TR

NHTSA ODI 10574209

BRAKES FAILED TO WORK. WOULD NOT STOP. *TR

NHTSA ODI 10542823

I WAS DRIVING WESTBOUND ON I-70 AROUND MP 129. THIS IS JUST BEFORE GLENWOOD CANYON. THERE WAS A FLASHING ICY ROAD SIGN AT WHICH TIME, I SIGNALED MY INTENTION TO MOVE TO THE RIGHT LANE WHICH I DID. I SLOWED DOWN AND PUT MY CAR IN 3RD. THIS WAS JUST BEFORE A CURVE TO THE RIGHT WHERE THE ROAD AND VISIBILITY NARROW. THE RIGHT LANE WAS COMPLETELY ICED OVER AS I REALIZED WHEN I GOT AROUND THE CURVE. IN FRONT OF ME, I SAW A PILEUP, BOTH LANES OF TRAFFIC WERE BLOCKED. I TAPPED MY BRAKES TO SLOW DOWN BUT BECAUSE OF THE ICE, I DID NOT STOP OR SLOW DOWN. I WENT AROUND ONE CAR STOPPED IN MY LANE TO AVOID HITTING IT FROM BEHIND. I WENT AROUND ON THE SHOULDER. I CONTINUED TO PUMP THE BRAKE. IMMEDIATELY IN FRONT OF ME WAS A SIERRA 4X 4 THAT WAS PERPENDICULAR TO THE LANE OF TRAFFIC AND IT WAS ALSO BLOCKING THE SHOULDER. I PLOWED INTO IT ABOUT THE MIDDLE OF THE TRUCK AT A RATE OF ANYWHERE OF 25 - 30 MPH. MY AIRBAGS DID NOT DEPLOY. MY DOG AND I WERE BOTH RESTRAINED AND WE SUFFERED NO INJURIES. MY CAR IS IN ALL LIKELIHOOD TOTALED. *TR

NHTSA ODI 10490026