Toyota faces a series of challenges as they begin replacing more than 100,000 engines in Tundra pickups and Lexus LX for a new recall in December. Do you have a 2022 or 2023 Toyota Tundra pickup? You may have a long wait, and here’s what you need to know.
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Toyota USA is confronted with a monumental task.
Toyota is gearing up to replace a staggering number of over 100,000 engines in Tundra pickups and Lexus LX SUVs due to a new recall in December. If you own a 2022 or 2023 Tundra pickup, brace yourself for a potentially lengthy wait.
Toyota says they are prepping their dealers now as they prepare to replace more than 100,000 engines and the task won't be easy.
A report from Automotive News (by subscription) says, "With each engine replacement requiring 13 to 21 hours to complete, dealerships must manage workflow so service bays remain available for other warranty and customer work. They'll also have to ensure they have the right loaner cars available. For example, a Corolla won't do for a customer using a Tundra for work."
It's Toyota's most extensive and most expensive recall in history.
See how long is the wait time and how Toyota is planning to handle it in this video from the Torque News Youtube channel and subscribe to stay in touch.
AN says that since July, when Toyota announced it would replace 102,292 V-6 Tundra and LX engines, the automaker has been consulting with its most experienced technicians and its Toyota and Lexus dealer councils on ways to handle the work without disrupting the service department or inconveniencing customers.
"We spent a lot of time in different trials internally in our own facilities, plus we used a couple of targeted dealers close to us in Plano to get their feedback on some ideas," said Kent Rice, Toyota group vice president of quality.
The Japanese automaker's approach "has been to try and reduce complexity for our technicians," Rice said. "We've spent a lot of time consulting different groups, including dealer councils, and they have been really helpful in their feedback."
Toyota estimates the Tundra recall will cost between $300 and $500 million.
What caused the Tundra recall?
In the 2022 and 2023 Tundra pickup and Lexus LX SUV models with the V35A twin-turbo 3.4-liter V-6 engine, internal passages in either block or cylinder heads were improperly cleaned. Small chips of metal, called "swarf," a result of the machining process, remained inside the engine after assembly.
The presence of these metal chips poses a serious risk. If they break loose, they can contaminate the engine's oil, leading to severe internal damage and potentially causing the engine to seize. This is a safety concern, especially if the vehicle stalls in traffic. Nearly 1,000 engines made in two Toyota plants have already failed due to this issue.
Customers may have a long wait.
Toyota has to replace the defective engines with new ones. Each engine replacement will require between 13 to 21 hours to complete. With 100,000 engines being replaced, a long line of customers will be waiting to get the work done.
The report says Toyota would not say how much each engine replacement costs. However, based on what Toyota budgeted for the safety recall, the cost per vehicle is expected to be about $3,000 to $5,000. Tundra owners are concerned because it could potentially affect the resale value of the affected vehicles before they get the engine replacement.
The faulty engines were produced in two Toyota plants — one in Japan and one in Alabama. Toyota won't say what caused the metal chips to remain in the engines. Still, it could result from a change in the manufacturing or cleaning process, new machinery, or defective tooling, not human error.
Toyota says it will supply nearly complete engine assemblies, including turbochargers, pulleys, tensioners, and other components, to its dealers to save technicians time in the Tundra engine replacement process.
The process is time-consuming.
To get the engine out, technicians must remove the vehicle's hood to access the engine bay. They will then drain fluids and disconnect ancillary parts — such as air conditioning and fuel system hoses, wiring harnesses, and the cooling system. The engine will then be unbolted from the transmission and engine mounts, lifted, moved forward, and tilted back to clear the vehicle's body.
New vehicle hoists will be installed first.
Rice said the replacement trials identified the need for a hoist that is different from what is used now to extract the engine without having technicians disassemble the grille, radiator supports, and such. He said Toyota is supplying dealerships with the new hoist and a different hook that raises the engine two feet higher than the hoists Toyota currently uses.
The defective Tundra engines may be used again.
The recalled engines will be returned to Toyota in the same packaging the new ones arrive in. Rice declined to say what would become of the recalled engines. However, because the engine block and heads are made of aluminum, they could be recycled to reduce some of Toyota's costs. Automotive News says some engines could be donated to trade schools and used for technician training.
Steve Gates, owner of Gates Auto Family, a 13-store group with three Toyota dealerships and one Lexus dealership in Kentucky, Tennessee, and Indiana, said, "We have four stores. If we had 50 customers that came in all at once for the recall, it would be a little challenging."
Customers will have to work with their local Toyota dealer.
Gates told Automotive News, "The dealers I have talked to are saying their customers are telling them they are not going to do this right away because they are not experiencing any problems. "It's probably only a small percentage of the 100,000 engines that will have any problems," he added. "There's some curiosity but no panic."
What should Tundra customers do now?
Toyota plans to notify customers in either late November or early December so that they can begin scheduling engine replacements. The recall will be launched officially in December. Several stores contacted by Automotive News said they had not received their new engine hoists.
Customers will get loaner vehicles.
Even though Toyota is paying for loaner trucks, some stores may have a shortage. Gates says he does not keep pickups in his store's loaner fleet but said he'll move some from his new vehicle inventory to give customers what they need while their vehicles are in the shop.
Do you own a 2022 or 2023 Toyota Tundra pickup? Have you experienced any engine problems? If so, click the red Add New Comment link below and let us know.
I am Denis Flierl, and have been serving as the Senior Torque News Reporter since 2012. My 30+ year tenure in the automotive industry, initially in a consulting role with every major car brand, and later as a freelance journalist test-driving new vehicles, has equipped me with a wealth of knowledge. I specialize in reporting the latest automotive news and providing expert analysis on Subaru you'll find here ensuring that you, as a reader, are always well-informed and up-to-date. Follow me on my X SubaruReport, All Subaru, WRXSTI, @DenisFlierl, Facebook, and Instagram.
Photo credit: Denis Flierl via Hendrick Toyota
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Toyota should offer current…
Toyota should offer current owners a generous trade-in package and put them in new trucks if the owners desire. They've done nothing to address the loss in value (both long and short term), the fact that owners currently can't sell or trade their trucks and the major inconveniences caused by the numerous recalls on the vehicle.
I agree with you, they…
I agree with you, they should refund owners or do what it takes to get them into a newer vehicle. Send the recall trucks to a factory for the refurb work and then sell them to fleet customers. This engine replacement fix will look bad on a Carfax report.
This is very concerning. I…
This is very concerning. I Owe a 2022 toyota thundra. On Friday 11.8.24 I suddenly lost engine power while driving on a main street at a pretty good speed. My 4 yr old daughter was sitting in the back seat. I immediately called the dealer who strangely enough had called me just the week prior. Options 1.sell the truck back. Option 2. Trade the truck in and get a new one. Option 3. Wait on the new engine which could take months.
I was concerned for the safety of my kids and for myself. Feeling hopeful I thought I could trade the truck and get a new one.
The dealership only offered 35k for my truck which I bought 2 years ago for 60k. They then offered me a pre-owned truck also at 60k.
My question is this. If the dealership sold me a lemon why am I then stuck with the price tag? This was no fault of mine but toyota's mistake. I have been to the dealership countless times with this truck for various recalls and programming updates, I even had to replace the break pad and disc in less that 2 years.
As someone who drove the thundra for 10 years I believe toyota should do right by their customers and not ask them to foot the bill. That is certainly not customer service.
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I own a 2022 Toyota tundra…
I own a 2022 Toyota tundra 1794 edition. And I did receive a letter from Toyota already.
Owned a 23 Tundra TRD Pro…
Owned a 23 Tundra TRD Pro Hybrid. First motor failed at 19,500 miles. Dealer had vehicle for 2.5 months and replaced the short block. Got vehicle back and 3 weeks and 500 miles later 2nd motor failed. I got rid of it last weekend. I would not accept anything short of a complete brand new crate motor. You've been warned.
I have a 2022 Tundra SR5…
I have a 2022 Tundra SR5 Crewmax that experienced a engine issue back in early July. I usually drive in "sport mode," and as
I went to pull out into traffic, and as you'all know, the throttle responds quick, the rpm went to 5-6,000rpm, and instantly my check engine light came on and I lost power. Fortunately for me, there was no one driving towards me, so I managed to steer my truck to the left onto a side road. I shut the truck off and waited for about 5 minutes and then fired it back up. A warning came across the infotainment screen telling me to contact the dealer. Ever since that incident, I've noticed what I refer to as hiccups, or a small knock. So I hope that Toyota will send me the recall papers soon. I have been driving it to and from work because I have no other option. I also hope Toyota does what is the right thing to do, Get your reputation back on track. Crack down on quality control. Learn your lesson and don't repeat it.
Similar to the Hyundai motor…
Similar to the Hyundai motor swaps. Hope they do a better job. Wife's 2015 Tucson died & it took 4 months to swap engines. I believe it was a cam issues so Hyundai swap is a remanufactered block. It was free but you have no idea (age, miles) about the 'news engine. They paid for loaner & it has been a couple years & no issues. Car is worth less so kids are still driving it.
My 2022 tundra has had at…
My 2022 tundra has had at least 6/8 times lost power while driving. On cruise control I lose 10/15 mpr in second.
Hard start at times. Spuders at times from a complete stop
My tundra is start to get a…
My tundra is start to get a rough idle and vibration while driving. 2023 year
22 thousand miles
My truck has already started…
My truck has already started Messing up. They also added a grill shutter to the 23 Tundra. I had to take mine in and have it replaced, thankfully Toyota took responsibility for it because they tried to charge 1800 to fix. But now my truck does not run right it idles way too high. I hope they get it done soon before the thing blows up on me.
I can only hope for many…
I can only hope for many more millions of recalls for Toyota over their lifetime for the way they treated the oil consumption ( reversed compression ring) problem. My 2008 Toyota Rav 4 sits in my yard with a locked engine not to mention peeling pearl white paint.
Maybe you can investigate or…
Maybe you can investigate or ask Toyota the following:
I have a 2023 Toyota Tundra SR5 TRD Off Road. Build date is 1/23, which falls within the range of the recalled engine build dates. Yet, Toyota has not included my truck in the recall. I have called Toyota customer service twice, but not straight answer. The local dealers said it was one person on the Alabama assembly line that did not clean the engines correctly, but if my engine was assembled there, why is it not on the recall list? I drive everyday waiting for the engine to croak. Not safe.
My lifters started making…
My lifters started making noises today and I was low on oil after a recent oil change at my local toyota dealership.
I was lucky. I got home backed in my driveway and my engine seized up. It turns over but it's like it's struggling to idle.
I gotta get my tundra towed tomorrow morning to the service center.
Imagine if Toyota had…
Imagine if Toyota had switched to all EV drivetrain, a Traction motor - that's the drive motor,takes a day to replace , not a week like the Twin Turbo V6, a battery pack for an EV is around $16,000 to $20,000, and to my knowledge only GMs Bolt have Battery pack recalls.
Good morning Denis! Great…
Good morning Denis!
Great article! I own a 2022 Toyota Tundra Platinum which is part of the engine recall.
Between the engine recall and the fuel line recall I've been without the use of my truck approaching almost 8 months! Based upon your article It could likely be approaching a year without my truck. Toyota won't do a buyback and they indicated this recall doesn't come under the Massachusetts Lemon Law. I do have a loaner but not to the level of my truck. Toyota will not provide an exact date for the engine replacement! It's unacceptable to be paying for a truck which I can't use and basically being kept in the dark by Toyota.
Experiencing fuel lose,…
Experiencing fuel lose, engines act like it wants to stall at stop lights and signs, rough idling, scare to drive it out of town, always in town.
Question:
Why not just give customers new 2024 trucks
My truck as I drive it at like it wants to stall
I told everybody not to buy…
I told everybody not to buy the newly designed motor in the Toyota tundra.1) because it was a new model altogether2) because this was one of the first Toyota motors with Turbochargers, which are usually not reliable Because of the stress that they put on the engine block and because it’s just a more complicated system. do not buy a redesign of any vehicle and definitely do not buy a turbo charged or supercharged engine.
I have a 2022 Toyota Tundra…
I have a 2022 Toyota Tundra TRD PRO hybrid. I’m worried because it has the same engine but because it is a hybrid they are not replacing the engine as they say it’s not a safety risk. This is a big concern as the engine could have the same issues and the resale value of the car has plummeted.
I have a 2023 platinum…
I have a 2023 platinum tundra and although it runs great...from time to time when I step on the pedal to accelerate, I loose power. My engine does not stall however the power failure does worry me because my truck does not respond as it should. It worries me especially on certain driving scenarios such as yielding left turns...imagine loosing power as your trying to get out of oncoming traffics way. I'm asking for suggestions/ remedies. please and thank you
2022 SR5 4x4: I loved my…
2022 SR5 4x4:
I loved my 2000 4Runner, but I thought a full sized pickup might be more practical for the many home improvements our cheap house would need. Boy, do I miss my 4Runner.
Our Tundra drives wonderfully, it has an insane amount of options (someone over ordered on this one) and it's Army green, which we love! But... I knew better than to buy the first model year and I did it anyway.
I/we are so disappointed in the mountain of recalls and trips to the dealership! Frankly, I'm worried I will never feel as confident in the reliability of a Toyota again... If you can't trust a Toyota, what do you do when it's time to get your next vehicle?! Toyota and Lexus WERE the gold standard... What now?
I think buying back or replacing the trucks with new CORRECTED and WARRANTIED vehicles is the least Toyota can do. They really should give us some money back or a company credit for the time and gas spent to fix every recall. Or give us a purchase option at cost and a fair trade value and/or rebate to cover the lose in valuation. If they were creative and proactive, they could spin this into a company and quality positive. We stand behind our vehicles and do the right thing when we find a mistake. REWARD your loyal customers, and have them forever!
Or continue to inconvenience us and lose a huge group of devoted buyers and marketing machines!
Fix it, if you can't, then replace it Toyota!! This isn't complicated... do the right thing.
I owned a 2022 Tundra SR5…
I owned a 2022 Tundra SR5. With rough idle, stalling, poor throttle response and the engine recall. With no expected delivery date on the replacement I went to the dealer to see what options I had to alleviate my growing concern of a failure.
Attempted to trade the truck in on a 2024 on the lot with a "big sale" going on without success. Dealer (the one I purchased it from and did all myself service with) was initially $15k over MSRP with my trade. Eventually they got it down to $6k after losing 3 hours to the process. Went back a second time because they sent a letter looking to make a deal. Still no deal.
With financing, extended warranty refunds, customer satisfaction and their decades old reliability reputation on the line Toyota still couldn't find a way to make enough money to solve the problem their COVID quality control created.
I'm now driving another brand and we dropped our Lexus for another brand. This was an easy one to solve regardless of the corporate spin. They could have offered swaps at the same trim level and financing, setup regional replacement shops and allowed business to flow as usual for the dealers and customers. They chose the cheap route to inconvenience everyone, take the reputation hit and customer dissatisfaction.
I'm guessing they got the outcome they wanted.