Toyota Recalls 2006-2007 Highlander Hybrid and RX 400h in the US

While The National Highway Traffic Safety Administration (NHTSA) is investigating the Highlander Hybrid over engine stalling issues, the North American division of Toyota announced today it has decided to conduct a voluntary safety recall involving approximately 45,500 Highlander Hybrid and 36,700 Lexus RX 400h vehicles, model year 2006 and 2007.

The automaker found there is a problem inside the Hybrid System Inverter in the respective cars. The Intelligent Power Module (IPM) located within it contains a control board with transistors.

“Certain transistors on the control boards in some of the subject vehicles were inadequately soldered and could be damaged from heat caused by a large current flow during high-load driving,” Toyota explains.

“If this were to occur, various warning lamps will illuminate on the instrument panel.  In most cases the vehicle will enter a fail-safe driving mode, resulting in reduced power in which the vehicle can still be driven for short distances.  In limited instances, the power supply circuit fuse could blow when the transistor is damaged. If the fuse blows, the hybrid system will stop and the vehicle will coast to a stop,” the company further adds.

However, Toyota is experiencing a problem with the necessary replacement parts for the moment. So a first notification letter will be issued in mid-July 2011, once the replacement parts are available.

Then, as the company managed to secure them in sufficient quantities, a second owner notification will be sent, advising owners to make an appointment with an authorized Toyota dealer to have the IPM inspected and if necessary replaced at no charge.