Toyota Motor Engineering & Manufacturing is recalling more than 126,000 trucks and luxury SUVs because of a manufacturing defect that could cause engines to fail suddenly while driving.
The problem stems from metal debris left over from manufacturing that can contaminate the engine and damage critical components.
The debris may cause the engine's main bearings to fail, potentially leading to engine knocking, rough running, or a complete stall while driving. A sudden loss of power at highway speeds significantly increases the risk of a crash, regulators warned.
Of the affected vehicles, 113,079 are Toyota Tundras produced between Nov. 22, 2021, and Feb. 14, 2024. The recall also includes 9,895 Lexus LX vehicles manufactured between Feb. 26, 2022, and April 2, 2024, along with 3,717 Lexus GX models built between May 31, 2023, and April 10, 2024.
Not all vehicles produced during these timeframes were sold in the United States.
The recall specifically covers V35A engines of a particular configuration manufactured during certain periods at select production plants. Metal shavings of a specific size and amount may not have been properly cleared from engines during assembly, allowing the debris to contaminate engine components.
When the contaminated engines operate under higher loads over time, the pressure on the main bearings, combined with the adhered debris, can cause bearing failure. The specific engine configuration in these vehicles makes the main bearings vulnerable to such damage, regulators said.
The company plans to mail interim notices to affected owners by Dec. 22, warning them of the safety risk. Additional letters will be sent once engineers finalize the repair procedure.
Dealers were notified of the recall on Nov. 6, and owner notifications are expected to be completed by Jan. 5, 2026.
This recall expands upon NHTSA recall number 24V381. Some engines with service parts produced before the current recall period were covered under the earlier recall. Other engines manufactured after the affected production period were built using improved processes and are under investigation, while some received an upgraded main bearing.
Other Toyota and Lexus models are not equipped with V35A engines of this configuration.
Affected owners can contact Toyota customer service at 1-800-331-4331. Toyota's internal recall numbers are 25TB14 and 25TA14, while Lexus is using recall numbers 25LB07 and 25LA07.