Every RAV4 Prime and Plug-in Hybrid recall, and what to do about each one

Quick picks

Every recall on a 2021 to 2026 plug-in RAV4

So Toyota called the plug-in RAV4 the RAV4 Prime from 2021 to 2024, and the RAV4 Plug-in Hybrid from 2025 on. NHTSA, the US government's car safety agency, lists recalls under those two names.

Now here's every recall NHTSA lists for both names, as of October 15, 2026. Each recall has an NHTSA number and a Toyota code, and the Toyota code is what shows on a dealer's repair order.

So ultimately, if you have a 2021 or 2022 Prime, the DC-DC converter recall is the one to check first. If you have a 2021 Prime, check the stall recall too. And if you have a 2026 Plug-in Hybrid, the power-loss software recall is the one that matters. My years to avoid guide shows how to look up any VIN. And the same guide lists the free Toyota programs, like the hybrid cable program, that cover the 2021 to 2024 Prime.

The DC-DC converter recall on the 2021 and 2022 RAV4 Prime (23V-478)

What the DC-DC converter is

So the DC-DC converter takes power from the big hybrid battery and turns it down to charge the 12-volt battery. The 12-volt battery is the small battery that powers the car's computers and lights, like the battery in a gas car. On the RAV4 Prime, the DC-DC converter sits under the rear seat, with its own cooling fan and duct.

What goes wrong with the DC-DC converter, and the fire risk

Now inside some DC-DC converters, a small part called the rectifying module was damaged during production at the supplier, Denso. Toyota's investigation pointed to static electricity in the supplier's factory.

Basically, when that damaged module fails, the module fails shorted instead of open. That means electricity keeps flowing through the module instead of being cut off. So current from the 12-volt battery keeps flowing through the module, and the module heats up. Toyota's recall report says that heat can damage parts in and around the converter, "increasing the risk of a vehicle fire."

And Toyota redesigned the rectifying module in late May 2022 so the module fails open instead. So a 2022 Prime built after May 27, 2022 already has the new design, and the recall won't show up on that car's VIN.

The 41°F charging rule, in plain words

So until the new DC-DC converter is in, Toyota says don't charge the Prime when the outside temperature is below 41°F, which is 5°C. Toyota's exact wording is to avoid charging "while the ambient temperature has been below, is below, or is expected to drop below 41 degrees Fahrenheit."

Basically, that means the overnight low counts, not just the temperature when you plug in. So if the temperature is 50°F at 6 p.m. but the overnight low is 35°F, Toyota says don't plug in that night.

Now here's why the cold matters. When the Prime is charging and the hybrid battery is cold enough to need its heater, extra current from the onboard charger also flows into the damaged module. That pushes the module's temperature higher. And Toyota's filing describes two cars:

• June 2021, Europe: A RAV4 Prime showed warning messages and smoke came from the rear seat on the highway. The cooling duct on the DC-DC converter had melted.
• February 2022, Canada: A RAV4 Prime had black smoke and a burned plastic smell the day after being plugged into a home charger. The right rear seat cushion had fire damage.

Toyota then found two things working together. Charging with the battery heater on, plus a clogged breather plug on the DC-DC converter itself, made the converter hot enough to melt holes in its aluminum case, and then the cooling duct caught fire. When Toyota filed the recall, it counted four field reports and two warranty claims from the US.

And keep in mind the 41°F rule is only about charging. Toyota never told owners to stop driving their Prime. Toyota's report says that if the module fails while driving, the car keeps running as long as the 12-volt battery has charge left, and a warning message comes on.

The warning messages for the DC-DC converter recall

So according to Toyota's owner letters, a failing DC-DC converter turns on the master warning light, and maybe a buzzer. Then one of these two messages shows on the gauge screen:

1. "Hybrid System Stopped Stop in a Safe Place Shift to P See Owner's Manual"
2. "Charging System Malfunction Stop in a Safe Place See Owner's Manual"

If you see either message, pull over when it's safe and call a Toyota dealer. And on a 2021 or 2022 Prime, run the VIN for 23V-478 first, using the steps in the used car section below.

When the DC-DC converter fix rolled out, by state

So Toyota filed the recall on July 12, 2023. The first owner letters that summer, coded 23TB07, said not to charge in the cold and that a fix might come in the fourth quarter of 2023. Then Toyota rolled out the actual fix by state, coldest states first.

Something to note is that Toyota's code for the DC-DC converter fix is 23TA07, while the early letters said 23TB07. So a dealer's repair order will show 23TA07.

What the DC-DC converter recall visit is like

So the fix is a new, improved DC-DC converter, and Toyota's letter says the job takes about an hour and a half. Toyota's letter says to call the dealer ahead to make sure the new converter is in stock. One owner's dealer had to order the converter first, and the wait was about a month. One owner said the job took 2 hours, and another said about 2.5 hours after the dealer quoted 4 to 6.

Now the tech removes the rear seat cushion to reach the DC-DC converter. And three owners on RAV4World got their Prime back with the rear seat not put back right, like a 1-inch gap at the left side of the cushion. One 2022 Prime SE owner needed two return trips before the shop foreman fixed the seat. Toyota's recall kit includes two new rear seat cushion lock hooks, the clips that hold the cushion down. So before you leave the dealer, I'd do these checks:

1. Push down on both rear seat corners. The rear seat cushion should be locked down with no gap.
2. Turn on the rear seat heaters, if your Prime has rear seat heaters, and make sure both sides warm up.
3. Look at the vent cover under the rear seat. The trim panel around the vent should sit flush, with no gap.

And a couple more things to keep in mind:

• The rental car offer is over. Toyota let dealers give owners who couldn't avoid cold charging a loaner or rental car, and Toyota paid the dealer $42 a day. But that offer ended 90 days after Phase 2 launched in spring 2024.
• You can get money back for an earlier repair. If you paid for this DC-DC converter repair before the recall, Toyota's General Reimbursement Plan lets you claim the money back.

How to confirm the DC-DC converter recall is done on a used 2021 or 2022 Prime

So the good news is that most of these Primes are fixed. NHTSA's latest report, filed October 15, 2025, shows 40,588 of the 43,442 RAV4 Primes and Lexus NX 450h+ in the recall as remedied. That count includes cars inspected and found not to need the part. That leaves roughly 2,200 still open, or about 5%. So on a used 2021 or 2022 Prime, the recall is likely done, but you'd want proof:

1. Run the VIN at toyota.com/recall and nhtsa.gov/recalls. Both lookups are free. If 23V-478 or 23TA07 shows as open, the converter hasn't been replaced. Keep in mind a blank NHTSA result means "no open recall," not written proof.
2. Ask the seller for the repair order showing 23TA07. Or have any Toyota service desk print the VIN's campaign history, which lists every recall done on that car.
3. In California, ask for the Proof of Correction Form. The dealer hands out a Vehicle Emissions Recall Proof of Correction Form after the repair, and California won't renew the registration until the recall is done.
4. Watch for a recall pop-up on the test drive. On a Prime with Toyota's connected services, the in-car recall pop-up only clears once the recall is done and the dealer's claim is approved. Pressing Snooze brings the pop-up back every 20 minutes. So a recall pop-up means the recall is still open.
5. Check the build date. The recall covers 2021 and 2022 RAV4 Primes built from November 25, 2019 to May 27, 2022. A 2022 built after late May 2022 already has the redesigned part. And 2023 and newer Primes aren't in the recall at all.

Something worth noting is that a Toyota Certified Used Prime can't be certified with an open safety recall. A dealer can still sell a non-certified used Prime with the recall open, as long as the dealer tells you. My used RAV4 buying guide covers what else to check on a used Prime, year by year.

Is it OK to charge a RAV4 Prime in the cold once the recall is done?

So yes. The 41°F rule was only Toyota's advice for Primes with the old DC-DC converter. Once 23TA07 is done, you can charge in the cold like normal.

Now the Prime still has its own normal cold-weather behavior. On Alaska and Canada cars, Toyota's manual shows the message "The Traction Battery Temp is low System put priority on charging to preserve battery condition." My plug-in RAV4 EV range guide covers winter range, and my RAV4 in snow guide covers preheating and winter charging.

When a charging error comes back after the DC-DC converter recall

So one Canadian 2021 Prime owner had "Hybrid System Malfunction" a second after charging started, in February 2024. The new recall converter didn't fix the error. Their dealer found an open relay on the battery side, part G386042010, quoted about $2,700 CAD, and at first refused to cover the relay under warranty.

Basically, a charging error on a Prime with 23TA07 already done is a different problem. So ask the dealer for the exact trouble codes, and check the Toyota bulletins below.

The 2021 RAV4 Prime cold-weather stall recall (23V-041): is it safe to drive?

So on 16,679 RAV4 Primes from the 2021 model year, flooring the gas pedal in EV mode in cold weather can shut the hybrid system down. Until the update, Toyota's advice was to avoid EV mode. There's no park-it or park-outside advisory, and the fix is software that takes about an hour.

My years to avoid guide covers the stall recall in full, including how to restart the Prime and how to confirm the fix. And my RAV4 Prime drive modes guide explains the drive mode messages.

The 2026 RAV4 Plug-in Hybrid power-loss recall (26V-659): is it safe to drive?

So Toyota says all 30,978 Plug-in Hybrids in the 2026 recall have the faulty motor computer software. But whether a car actually fails "depends on the conditions."

Basically, the problem starts when you switch the car on, if the motor computer doesn't finish its start-up checks. Then warning lights come on once you reach a speed that needs the higher-speed motor mode. After that, the car goes into a front-drive limp mode at limited speed, or the system shuts off.

Now there's no do-not-drive or park-outside advisory. Dealers have the software now, and owner letters go out November 22 to December 6, 2026. The fix doesn't come over the air, so you'd book a dealer visit. My 2026 RAV4 problems guide covers the 26V-659 recall in full.

"Charging System Malfunction" on a RAV4 Prime: the three charging messages

So the Prime actually has three different charging messages, and Toyota's manual treats each one differently. The wording is the same in the 2021 to 2024 Prime manuals, and the 2026 Plug-in Hybrid manual has the same messages.

Now here's what I'd do when one of the charging messages shows up:

1. If the message says "Stop in a Safe Place," pull over when it's safe. Toyota's manual says continuing to drive may be dangerous.
2. On a 2021 or 2022 Prime, run the VIN for 23V-478 first. If the DC-DC converter recall is open, stop charging in cold weather and book the recall.
3. If the message only shows while plugged in, unplug. Then try another charger or outlet, which is Toyota's manual's advice for other charging errors. If the message comes back, have the dealer read the codes.
4. Ask the dealer for the exact trouble code, and whether bulletin T-SB-0007-21, T-SB-0067-22 or T-SB-0021-21 applies. The three bulletins are in the next section.

And if you see a different warning light or message, my RAV4 warning lights guide covers the rest. A "Hybrid System Malfunction" message on a Prime can also come from a corroded hybrid cable, which my hybrid cable corrosion guide explains.

The three Toyota bulletins behind charging problems on a RAV4 Prime

So a technical service bulletin, or TSB, is a repair guide Toyota sends dealers for a known problem. A TSB isn't a recall, so a TSB repair is only free while the warranty the bulletin names still covers the car. Here are the three bulletins that cause charging warnings on a Prime, plus the other causes.

Now the 6.6 kW onboard charger in T-SB-0067-22 is the part that charges the hybrid battery from the plug. Toyota's replacement 6.6 kW charger is part G9099-42063, listed at $2,790.16 for the part alone, checked October 15, 2026. One 2021 XSE owner was quoted about $4,000 installed at 79,000 miles, out of warranty. My plug-in home charging guide explains the 3.3 kW and 6.6 kW chargers.

And something to note about Toyota's warranty. On the 2021 Prime, the 8-year, 100,000-mile hybrid system warranty lists an "inverter with converter," and the hybrid battery itself is covered for 10 years or 150,000 miles. But Toyota's warranty booklet doesn't say whether the under-seat DC-DC converter counts as part of the "inverter with converter." So ask for the trouble code and the bulletin number, because each TSB names the warranty that covers the repair.

Check engine light with code P1CCC96 on a 2021 RAV4 Prime: the DC/DC bolt fix

So P1CCC96 means "DC/DC Converter Enable Component Internal Failure," and the check engine light comes on with the code. Toyota's bulletin for P1CCC96 is T-SB-0007-21, from February 3, 2021.

Basically, the bolts that hold the DC/DC converter's ground connection had a plating problem, which causes high resistance. So the fix is four new ground bolts on the DC/DC converter bracket. Here's what the bulletin covers:

• Which RAV4 Primes: 2021 RAV4 Primes built early in production. The bulletin lists a cutoff VIN for each trim code, so the dealer checks your VIN.
• The fix: The tech takes out the rear seat and replaces the four ground bolts with the new part, 90119-A0383, listed at $1.49 each, checked October 15, 2026. The bulletin lists 1.2 hours of labor.
• Not a do-it-yourself job: The bolt job is high-voltage work done with insulated gloves, so leave the bolt job to a Toyota dealer.
• Who pays: The bulletin says the repair is covered under Toyota's basic warranty, 3 years or 36,000 miles. Every 2021 Prime is now past 36 months, so today an owner normally pays for the bolt job. Toyota doesn't publish a price, so ask the dealer for a quote with the bulletin's 1.2 hours of labor and four bolts.
• Confirm the cause first: The bulletin's first step is to confirm the check engine light is on with P1CCC96 stored. So the code alone doesn't prove the bolts are the cause.

Now keep in mind P1CCC96 and recall 23V-478 are two different things, even though both involve the DC/DC converter on 2021 Primes. The P1CCC96 bulletin replaces the bolts that ground the converter. The 23V-478 recall replaces the converter itself. So a 2021 Prime could need both.

And a basic code reader will show a P1CCC code with the check engine light. But the "96" part and other hybrid codes may need a Toyota-level scan tool, like the one the dealer uses. My RAV4 hybrid battery check guide covers what an OBD2 phone app can and can't read.

The DC/DC converter vent filter under the rear seat on a 2021 to 2024 Prime

So this is the maintenance item a lot of Prime owners miss. Toyota's 2021 to 2024 RAV4 Prime maintenance guides say to look at the DC/DC converter air intake filter every 5,000 miles. If the filter has dirt or dust on it, clean the filter. And Toyota says to clean the filter every 20,000 miles either way.

Now here's what Toyota's manual says about the DC/DC converter vent:

• Where the vent is: The DC/DC converter vent is under the rear seat.
• Don't block the vent: Keep seat covers, plastic and luggage off the vent.
• How to clean the vent and filter: Use a vacuum. Don't blow the vent out with an air gun.
• Watch what you carry: Don't carry large amounts of water, like water cooler bottles, because a spill onto the DC/DC converter can damage the converter.
• The warning if the vent clogs: "Maintenance required for DCDC converter cooling parts See Owner's Manual."

My RAV4 hybrid battery check guide shows how to clean the Prime's DC/DC converter filter step by step, since the cleaning steps are the same as the RAV4 Hybrid's battery filter.

Something to note is that Toyota's 2025 and 2026 RAV4 Plug-in Hybrid maintenance guides don't list the DC/DC filter check, and the 2026 manual has no DC/DC vent section. And a dirty cabin vent filter is not what caused the recall fires. Toyota's recall report points to a clogged breather plug on the DC-DC converter itself, which is a different part.

What RAV4 Prime owners report about the DC-DC converter and charging

So here's what owners have reported, by count:

• NHTSA complaints: Of 99 complaints on the 2021 Prime and 22 on the 2022 Prime, 29 and 5 mention the DC-DC converter recall, the converter or the charging system.
• Waiting for parts: About 30 of those complaints were about waiting for the recall part, filed from October 2023 to May 2024. Many came from snowbelt states, like upstate and western New York. None of those complaints reported an actual fire.
• Rear seat after the recall: 3 owners on RAV4World got their Prime back with the rear seat not put back right.
• The 6.6 kW onboard charger: 3 owners reported onboard charger problems. One got "Charging System Malfunction" and a $4,000 quote. Another complained that T-SB-0021-21 is only free under the 60,000-mile powertrain warranty. And a third reported arcing and a burning smell when plugging into a Level 2 charger.
• A hot charge handle: 1 owner of a 2021 Prime found the charge handle extremely hot and stuck in the port in May 2023. NHTSA didn't tie that report to the recall.
• A charging error after the recall: 1 Canadian owner needed a new relay on the battery side after the recall converter didn't fix their error.

Plug-in RAV4 recalls in Canada and Australia

So the 2026 power-loss recall covers about 7,846 Plug-in Hybrids in Canada. And in Australia, Toyota recalled 5,925 RAV4 plug-in hybrids from the 2026 model year on October 9, 2026. My 2026 RAV4 problems guide covers both.

Who to call about a plug-in RAV4 recall

• Toyota customer service: 1-800-331-4331, the number on every Toyota recall.
• Toyota Brand Engagement Center: 1-888-270-9371, the number on the 23V-478 letters.
• NHTSA Vehicle Safety Hotline: 1-888-327-4236.

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