2021-2022 Toyota RAV4 Prime Dc and Dc Converter Recall (23V478)
Toyota Motor Corporation · 43,442 vehicles · Reported July 12, 2023
Toyota Motor Corporation is recalling 43,442 2022 Lexus NX450H+; 2021-2022 Toyota RAV4 Prime vehicles. The electric current rectifying module contained within the DC-DC converter may have been damaged during production, which can result in an electrical short-circuit. A short circuit can cause the DC-DC converter to overheat, increasing the risk of a vehicle fire. Dealers will make the repair free of charge.
Recall 23V478 at a glance
| NHTSA campaign number | 23V478000 |
|---|---|
| Manufacturer recall number | 23TB07/23LB01 |
| Date reported to NHTSA | July 12, 2023 |
| Manufacturer | Toyota Motor Corporation |
| Vehicles | 2022 Lexus NX450H+; 2021-2022 Toyota RAV4 Prime |
| Units affected | 43,442 |
| Component | Electrical System > Propulsion System > Dc / Dc Converter |
| Safety risk | A short circuit can cause the DC-DC converter to overheat, increasing the risk of a vehicle fire. |
| Fix | Available at dealers |
What is wrong with the 2021-2022 Toyota RAV4 Prime in recall 23V478?
The electric current rectifying module contained within the DC-DC converter may have been damaged during production, which can result in an electrical short-circuit.
Toyota Motor Engineering & Manufacturing (Toyota) is recalling certain 2021-2022 RAV4 Prime and 2022 Lexus NX450h+ plug-in hybrid electric (PHEV) vehicles. The electric current rectifying module contained within the DC-DC converter may have been damaged during production, which can result in an electrical short-circuit.
Is it safe to drive a 2021-2022 RAV4 Prime with recall 23V478?
NHTSA has not told owners to stop driving, but the risk is real: A short circuit can cause the DC-DC converter to overheat, increasing the risk of a vehicle fire.
NHTSA describes the risk this way: A short circuit can cause the DC-DC converter to overheat, increasing the risk of a vehicle fire.
NHTSA has not issued a do-not-drive or park-outside warning for this recall. Still, get the repair done as soon as it is available, and stop driving if you notice symptoms related to the dc and dc converter.
Which vehicles are included in recall 23V478?
Recall 23V478 covers 43,442 vehicles: 2022 Lexus NX450H+; 2021-2022 Toyota RAV4 Prime.
NHTSA lists 43,442 vehicles in this campaign. Not every vehicle of these models and years is included, so check your VIN.
| Model years | Make | Model |
|---|---|---|
| 2022 | Lexus | NX450H+ |
| 2021-2022 | Toyota | RAV4 Prime |
What is the fix for the RAV4 Prime dc and dc converter recall?
Yes. Owners are advised not to charge their vehicles when the ambient air temperature is below or expected to drop below 41 degrees Fahrenheit (5 degrees Celsius).
Owners are advised not to charge their vehicles when the ambient air temperature is below or expected to drop below 41 degrees Fahrenheit (5 degrees Celsius). Dealers will replace the DC-DC converter, free of charge. Owner notification letters were mailed December 29, 2023. Owners may contact Toyota's customer service at 1-800-331-4331. Toyota's number for this recall is 23TB07/23LB01.
When was recall 23V478 announced?
Toyota Motor Corporation reported recall 23V478 to NHTSA on July 12, 2023. NHTSA lists the owner letter date as December 29, 2023.
| Date | What happened |
|---|---|
| July 12, 2023 | Toyota Motor Corporation filed the defect report with NHTSA; NHTSA assigned campaign 23V478000. |
| December 29, 2023 | Owner notification letters mailed (per NHTSA). |
This recall was filed 39 months ago. If your RAV4 Prime was built in that window, the VIN check below is the way to confirm it is included.
How do I check if my RAV4 Prime is part of recall 23V478?
Enter your 17-character VIN at nhtsa.gov/recalls. If recall 23V478 is open on your RAV4 Prime, it will be listed there.
The fastest check is NHTSA’s VIN lookup. Type in the 17 characters from your registration or insurance card. Because only some 2021-2022 RAV4 Prime vehicles are included, the VIN check is the only reliable way to know. A brand-new recall may take several days to show up.
What should RAV4 Prime owners do about recall 23V478?
Check your VIN, schedule the free recall repair, and keep a repair order for every dealer visit.
- Check your VIN at nhtsa.gov/recalls to confirm recall 23V478000 applies to your RAV4 Prime.
- Call a Toyota dealer and schedule the recall repair. Ask how long the repair takes and whether parts are in stock.
- Keep a copy of every repair order. Check that each one lists your complaint, the mileage, and the dates in and out.
- Keep a simple log of any dc and dc converter symptoms with dates and mileage. Video of a warning light or the problem happening is strong evidence.
- Count the days the vehicle is at the dealer. Days out of service add up toward California's 30-day presumption.
- If the recall repair does not fix it, or the vehicle keeps going back for the same issue, talk to a lemon law attorney.
What are RAV4 Prime owners reporting to NHTSA?
Owners have filed 122 complaints with NHTSA about these vehicles since 2020, 44 of them about the ev and hybrid battery.
Since recall 23V478 was reported on July 12, 2023, owners have filed 40 complaints with NHTSA about the ev and hybrid battery on these vehicles. 2 of them (5%) describe the same problem happening more than once or coming back after a repair attempt.
How we counted: we matched NHTSA owner complaints for the model years in this recall that list the ev and hybrid battery and were received on or after July 12, 2023, then flagged narratives that describe a repeat failure or a problem returning after a dealer repair, recall service or software update. Data from NHTSA, accessed October 1, 2026. Complaints are unverified owner reports and may involve a related ev and hybrid battery issue rather than this exact defect; automated text matching can miss or misread some reports.
NHTSA’s public complaint database lists 122 owner complaints filed since 2020 for the vehicles in this recall, and 44 of them involve the ev and hybrid battery. Complaints are reports from owners and have not been verified by NHTSA, but a high count for the same component is a sign the problem is widespread.
- 2021 Toyota RAV4 Prime: 99 complaints in total, 37 about the ev and hybrid battery
- 2022 Toyota RAV4 Prime: 21 complaints in total, 7 about the ev and hybrid battery
- 2022 Lexus NX450H+: 2 complaints in total, 0 about the ev and hybrid battery
Examples of what owners have reported to NHTSA (unverified excerpts):
The vehicle generated an error message "Plug In Charging System Malfunction" warning on the dash. The remedy is a Toyota T-SB-0021-21 which requires a software upgrade to fix the air fan sensor reading to the charging unit.
2021 Toyota RAV4 Prime owner, WA, NHTSA complaint 11734723, filed April 29, 2026
Observed arcing noises and strong electrical fire smell upon plugging in L2 EVSE charging cable. MIL lit, Hybrid Vehicle Charging System codes active; vehicle refused to charge afterwards. Self-diagnosed and repaired defective 6.6 kW onboard charger. See pics of clear arcing damage withing charging unit – possible fire risk.
2021 Toyota RAV4 Prime owner, TX, NHTSA complaint 11742590, filed June 7, 2026
The 2021 RAV4 Prime has a known defect with the heat pump causing an alarming sound to be heard within about a 1 minute of startup. The grinding noise causes distraction as it is extremely loud and occurs generally while backing out/maneuvering in tight areas.
2021 Toyota RAV4 Prime owner, CO, NHTSA complaint 11443354, filed December 10, 2021
Can recall 23V478 make my RAV4 Prime a lemon in California?
Not by itself. A recall repair that fails, or repeat dealer visits for the same defect, can support a California lemon law claim.
A recall by itself does not make a car a lemon. Under California's Song-Beverly Consumer Warranty Act, what matters is whether a defect covered by the warranty substantially impairs the vehicle's use, value or safety, and whether the manufacturer or its dealers fixed it within a reasonable number of attempts (Civ. Code 1793.2(d)).
High-voltage battery and drive system defects in EVs and hybrids can mean reduced range, charging faults, loss of drive power or a fire risk. These repairs often need parts on backorder, so days out of service add up quickly.
A remedy is available. Many vehicles are fixed on the first try. If the problem returns after the recall repair, or the 2021-2022 Toyota RAV4 Prime has needed other repairs for the same defect, those visits count toward a lemon law claim.
Civil Code 1793.22(b) sets out a presumption that applies in the first 18 months or 18,000 miles: two or more repair attempts for a defect likely to cause death or serious bodily injury, four or more attempts for the same defect, or more than 30 total days out of service for repairs. Written notice to the manufacturer is required in some cases. Owners outside that window can still have a claim.
An owner who prevails in a lemon law case can recover reasonable attorney fees and costs from the manufacturer (Civ. Code 1794(d)). You pay nothing, win or lose. We are paid only if you win, and the manufacturer pays our fees, including in settlements. If a case is lost, our firm covers the costs.
In our cases, a recall repair visit counts as a repair attempt, and it's strongest when the owner complained about the problem before the recall came out. A recall shows the defect is real and that enough owners reported it for the manufacturer to issue a fix.
Recall repairs depend on parts. Owners can wait days, weeks or months, usually about one to three months in our cases, and those days count toward California's 30-day out-of-service rule.
The biggest mistake I see is waiting too long. The mileage offset starts at your first repair visit for the problem, so the sooner you take it in, the better. If the problem comes and goes, take it in when it happens. You can't go back to that date later.
If you get a recall notice, call a lemon law attorney right away. You may have taken the car in for the same problem before and forgotten, or there may be other recalls related to it.
Jacob Shayesteh, Esq. (SBN 362320), Founder and Managing Attorney. Quotes lightly edited for clarity. Prior results do not guarantee a similar outcome.
Has your RAV4 Prime been back to the dealer for this problem?
Call 877-536-6620Other Toyota RAV4 Prime recalls
Frequently asked questions about recall 23V478
Did the recall 23V478 fix work?
Since recall 23V478 was reported on July 12, 2023, owners have filed 40 complaints with NHTSA about the ev and hybrid battery on these vehicles. 2 of them (5%) describe the same problem happening more than once or coming back after a repair attempt. If your vehicle still has the problem after the recall repair, go back to the dealer, get a repair order, and talk to a lemon law attorney.
When will owners be notified?
According to NHTSA, owner notification letters were or are scheduled to be mailed December 29, 2023.
Is the 23V478000 recall repair free?
Yes. Safety recall repairs are done free of charge at authorized dealers.
How do I know if my RAV4 Prime is part of recall 23V478000?
Enter your 17-character VIN in NHTSA's recall lookup at nhtsa.gov/recalls, or call a dealer. The VIN is on your registration, insurance card and the lower corner of the windshield.
Can a battery recall reduce my EV's range?
Some battery recalls limit the state of charge or range until a module or pack is replaced. Check your owner letter for any interim limits, and keep notes if range or charging changes after the repair.
Does the recall fixing my car mean I have no case?
Not necessarily. Even if the recall repair fixed it, you may still have a case, and a car that's a year or more old can still qualify.
Do used cars qualify for California lemon law?
We take certified pre-owned, demo and dealer vehicles. Since the California Supreme Court's Rodriguez decision in 2024, ordinary used cars generally do not qualify.
How long does a recall lemon law case take?
Recall-related cases typically resolve in one to three months from your first call. Prior results do not guarantee a similar outcome.
What does a lemon law attorney cost?
You pay nothing, win or lose. We are paid only if you win, and the manufacturer pays our fees, including in settlements. If a case is lost, our firm covers the costs.
Sources
- NHTSA recall record 23V478000 (recall report and owner letters are posted there)
- NHTSA complaints and recalls data, accessed October 1, 2026
- California Civil Code 1793.2 and 1793.22
Attorney advertising. America’s Lemon Lawyer is a trade name of Wynn Law Group, APC. Responsible attorney: Jacob Shayesteh, Esq. (SBN 362320). This page is general information, not legal advice. America’s Lemon Lawyer is not affiliated with NHTSA or Lexus, Toyota. Prior results do not guarantee a similar outcome.