This apparently did not happen with certain recently built examples Toyota Camry hybrids and Toyota Corolla Cross Hybrids.
The converter bolt may become loose
The Japanese car manufacturer does with 55,405 of these vehicles being recalled because a machine at supplier Denso’s factory in Maryville, Tennessee, incorrectly tightened a bolt in the inverter that converts power from the hybrid battery to the electric motor that drives the wheels.
Toyota told the National Highway Traffic Safety Administration today that the improperly torqued bolt could cause incomplete contact at the converter terminal, or the bolt could become loose in the converter assembly.
Risk of crashes and fire
“If either occurs, an open circuit may occur that activates a warning lamp and, in some cases, could potentially lead to a simultaneous activation of limp mode or loss of motive power,” Toyota says in its recall notice. “The loss of motive power from a vehicle while driving at higher speeds can increase the risk of a crash.”
If that bolt loses contact while the ignition is turned on and the bolt becomes loose in the converter assembly, “this could lead to a short circuit that could generate enough heat to cause thermal damage to components in and around the converter assembly, increasing the risk of fire.”
‘Low torque bolt’
The problem was discovered in early November this year when Toyota received a field report claiming a vehicle could not be started. It was later discovered that a bolt in the inverter assembly had come loose and was lying on the circuit board.
“The supplier used this information to assess the assemblies currently in its factory and discovered that additional assemblies had a specific low torque bolt,” due to a changed setting on a machine at Denso’s factory.
Cure in the making
Toyota says its engineers are working on a fix and the fix will be done free of charge. Notification letters will be emailed to vehicle owners on January 30, 2026, explaining the safety risk.
These are the affected vehicles:
- 2025 Toyota Camry Hybrid (2,435 units produced between August 26, 2025 and November 18, 2025).
- 2026 Toyota Camry Hybrid (49,209 units produced between August 26, 2025 and November 18, 2025).
- 2026 Toyota Corolla Cross Hybrid (3,761 units produced between August 27, 2025 and November 25, 2025).
Cars built in Kentucky or Alabama
The affected vehicles were assembled at Toyota’s plant in Georgetown, Kentucky, or at Mazda Toyota Manufacturing USA’s plant in Madison, Alabama.
Owners can contact Toyota Customer Service at 1-800-331-4331. Toyota’s number for this recall is 25TB15/25TA15, and this link will take you to the NHTSA recall portal for additional information.
Source: Toyota/NHTSA
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