[Tazio Nuvolari]

Many hybrid owners are hoping the new cable and connector cover will fix this corrosion issue and that Toyota will issue a recall or a statement that they will cover all repairs under warranty. I wish to point out the roof leak issue relating to the crappy roof rail trim gasket seals that effects BOTH hybrids and gas models and has occurred to thousands of RAVs. There has NEVER been a recall and after the basic 3 year warranty runs (at least in gas models) the owner must pay for all repairs.

 

[SLS Artemis]

Every car is going to have its issues. You just have to decide what you're willing to tolerate and what can be fixed. Whether you do it yourself or you pay someone to do it.

 

[Eldorado19h]

if there is a brave manufacturer of aftermarket parts start making the connector so we can cut and solder the rusting part.
if the electrical motor part rusts that's a bummer

 

[mikelets456]

Every car is going to have its issues. You just have to decide what you're willing to tolerate and what can be fixed. Whether you do it yourself or you pay someone to do it.

That's not the issue. It's being denied coverage to FIX the problem under the hybrid warranty that's the concern....It's their obligation to do so.

 

[lucgallant]

My opinion based on taking mine apart was the amount of sand and dirt trapped in the enclosed orange case. It traps the salt water and takes a long time to dry out. It could stay wet most of winter with salt in northern states really accelerating the process. I think the open bottom on new connectors allows the dirt and sand to fall out and slows down the corrosion process greatly because it will be dry a higher percentage of time. I backed up on some service ramps and had plenty of room to work on it.

Can you or someone else that has performed an inspection comment on whether you can take the orange boot off without unplugging the connector?

 

[RobertB]

Can you or someone else that has performed an inspection comment on whether you can take the orange boot off without unplugging the connector?

Yes you can. Zip tie on lower part has to be cut off to remove boot and replaced when finished.

 

[Keith_A]

I inspected my connector today. Don't have a lot of mileage on the vehicle, and didn't note any corrosion. However there was clearly evidence of dirt and water inside the orange cover so I decided to do something about it.
1. I removed the orange cover and drilled 2 weep holes in the bottom of the cover.
2. Sprayed the inside of the covered area with CRC Heavy Duty Corrosion Inhibitor.
3. Replaced the orange cover.
4. Applied Permatex Dielectric Grease around black rubber seal on connector that plugs into the motor/generator.
5. Re-attached connector to motor/generator.

(Not recommending that others do this. I don't want the legal liability...)

Keith

 

[SLS Artemis]

That's not the issue. It's being denied coverage to FIX the problem under the hybrid warranty that's the concern....It's their obligation to do so.

Google CP4 pump failure and the cost of this repair will feel miniscule. Parts alone to convert mine was $4,000 with me doing all of the work. If there is a failure the cost is $10K-$15K.

If the wiring harness is failing now it will fail later unless there are significant design changes and it won't matter if you're in warranty or out of warranty.

 

[RavioliXSE]

I inspected my connector today. Don't have a lot of mileage on the vehicle, and didn't note any corrosion. However there was clearly evidence of dirt and water inside the orange cover so I decided to do something about it.
1. I removed the orange cover and drilled 2 weep holes in the bottom of the cover.
2. Sprayed the inside of the covered area with CRC Heavy Duty Corrosion Inhibitor.
3. Replaced the orange cover.
4. Applied Permatex Dielectric Grease around black rubber seal on connector that plugs into the motor/generator.
5. Re-attached connector to motor/generator.

(Not recommending that others do this. I don't want the legal liability...)

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Keith

I would caution others against making mods to this, as it will likely give Toyota even more reason to not honor the warranty.

 

[Danajt17]

Hello Rav4 World!
I have the same issue as OP. Was told by dealer that replacing both the High Voltage Wire Harness and Generator Motor would cost 6700.00 CAD. (Have the official quote).
I own a 2020 Rav4 XLE Hybrid with 70,000kms
This takes me out of basic coverage. However I thought my hybrid warranty would cover it based on the warning messages of hybrid malfunction.
Anyways I contacted my reliable salesman in Collingwood (Timmins is as sketchy as they go). He said he had similar issue but car was under warranty and it was put under the basic warranty and not the hybrid - he said I may be screwed. But he told me to call Toyota Canada and raise a Vista report which should move me up the line. Toyota Canada person was very sympathetic and wrote everything down..
They then told me based on my Toyota loyalty - whatever - that they pushed it forward to a case manager and I would get a response in 3-5 business days. For what its worth the person agreed that it shouldnt come out of pocket - corrosion on a 2020 vehicle. They also said to leave it and not fix until they responded - luckliy I have a very reliable Tacoma lol.
Another thing that will help my case is this forum...as I believe Toyota changing the part is acknowledgment of it being faulty and they should have let there customers know - this is the practice in my line of work with any changes in machinery.
Anywho we will see what response I receive. But that call from my wife for 6700 was a shocker. I buy Toyotas to avoid this.
Also the reasoning of it not being a hybrid part....can someone post a picture of a high voltage wiring harness on there non hybrid vehicle?? Ya doesnt exist...I will not let this one go. Please keep me updated on ur cases and I will on mine as well.

 

[Robert70]

I would caution others against making mods to this, as it will likely give Toyota even more reason to not honor the warranty.

What's the point, it's going to be out of warranty by the time it completely shorts out! This reminds me of my 05 4 cylinder Tacoma. There's a cheap plastic bypass heater hose, down under the in-take manifold. It cracked and the coolant leaked out, couldn't see it leaking. The temperature sending unit was mounted high in the block. Only gave a true temperature reading if it was in contact with coolant. Ended up warping the aluminum head before finding out the problem!

 

[Robert70]

I inspected my connector today. Don't have a lot of mileage on the vehicle, and didn't note any corrosion. However there was clearly evidence of dirt and water inside the orange cover so I decided to do something about it.
1. I removed the orange cover and drilled 2 weep holes in the bottom of the cover.
2. Sprayed the inside of the covered area with CRC Heavy Duty Corrosion Inhibitor.
3. Replaced the orange cover.
4. Applied Permatex Dielectric Grease around black rubber seal on connector that plugs into the motor/generator.
5. Re-attached connector to motor/generator.

(Not recommending that others do this. I don't want the legal liability...)

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Keith

Wanted to ask, did you besides having your car not running. Did you pull any fuses before working on this high voltage connection?

 

[RobertB]

I inspected my connector today. Don't have a lot of mileage on the vehicle, and didn't note any corrosion. However there was clearly evidence of dirt and water inside the orange cover so I decided to do something about it.
1. I removed the orange cover and drilled 2 weep holes in the bottom of the cover.
2. Sprayed the inside of the covered area with CRC Heavy Duty Corrosion Inhibitor.
3. Replaced the orange cover.
4. Applied Permatex Dielectric Grease around black rubber seal on connector that plugs into the motor/generator.
5. Re-attached connector to motor/generator.

(Not recommending that others do this. I don't want the legal liability...)

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Keith

You got her! Excellent writeup!

 

[camfused]

Has anyone in the southern US seen this problem (I am in NC), or is this only an issue for the folks who live in areas that get snow?

 

[Eldorado19h]

Has anyone in the southern US seen this problem (I am in NC), or is this only an issue for the folks who live in areas that get snow?

Snow and salt for now affects the connection in 2 years
Will it affect hybrids from the south in 10-15 years? I don’t think so. Possibly the ones close to the ocean.

 

[lesz]

I inspected my connector today. Don't have a lot of mileage on the vehicle, and didn't note any corrosion. However there was clearly evidence of dirt and water inside the orange cover so I decided to do something about it.
1. I removed the orange cover and drilled 2 weep holes in the bottom of the cover.
2. Sprayed the inside of the covered area with CRC Heavy Duty Corrosion Inhibitor.
3. Replaced the orange cover.
4. Applied Permatex Dielectric Grease around black rubber seal on connector that plugs into the motor/generator.
5. Re-attached connector to motor/generator.

(Not recommending that others do this. I don't want the legal liability...)



Keith

While making such modifications seems logical, what makes me hesitate with regard to doing something like this is that I don't want to give Toyota an added reason to decline a warranty claim should there be a problem down the road.

 

[Kmvreter]

While making such modifications seems logical, what makes me hesitate with regard to doing something like this is that I don't want to give Toyota an added reason to decline a warranty claim should there be a problem down the road.

I have no problem with doing this at 3yr/60000km, the minute I am out of basic warranty, unless they extend the warranty. Even then, I'll make it an inspection item to make the connector last as long as I can.

 

[lesz]

I have no problem with doing this at 3yr/60000km, the minute I am out of basic warranty, unless they extend the warranty. Even then, I'll make it an inspection item to make the connector last as long as I can.

At this point, we have no way of knowing whether or not Toyota will decide to make this a warranty eligible repair, whether because it is their own choice or because they are forced to do so, but this harness is a part of the hybrid system, and the hybrid system has a much longer warranty than either the bumper-to-bumper warranty or the power train warranty. So, doing these modifications could risk the possibility that Toyota could claim that the modifications caused a problem that allows them to deny warranty claims well past those covered by the 3 year bumper-to-bumper warranty.

 

[14v6]

At this point, we have no way of knowing whether or not Toyota will decide to make this a warranty eligible repair, whether because it is their own choice or because they are forced to do so, but this harness is a part of the hybrid system, and the hybrid system has a much longer warranty than either the bumper-to-bumper warranty or the power train warranty. So, doing these modifications could risk the possibility that Toyota could claim that the modifications caused a problem that allows them to deny warranty claims well past those covered by the 3 year bumper-to-bumper warranty.

There are exclusions. It clearly says specific hybrid components. The language is from a Moroney sticker

The New Vehicle Limited Warranty provides 3-year/36,000 mile basic coverage, 5-year/60,000 mile powertrain coverage, 5-year/unlimited mile corrosion perforation coverage, 8-year/100,000 mile coverage for specific Hybrid components and 10-year/150,000 mile coverage for the Hybrid Battery. Some components may have longer coverage under California emissions warranty (applicable in CA, CO, CT, DE, ME, MD, MA, NJ, NY, OR, PA, RI, VT, WA. See Warranty and Maintenance Guide for details. An extended service contract may be available for the vehicle.

Even if the harness was covered, they could still say they get a corrosion exclusion. Based upon their stance with the Canadian Service bulletin it looks like there won't be any support past the 3/36 or earlier (if over mileage). Toyota needs to take responsibility for this crappy design. Also, how does any hybrid component fail to fall under the hybrid or the powertrain warranty? Basically, when comparing gas to hybrid, the gas has better coverage for components that propel the car. On paper it doesn't make sense to justify the hybrid because there is more risk for uncovered parts early on. Folks don't realize this when Toyota puts out press releases saying that all hybrids are covered for 8 years/x miles and the battery 10 years/x miles. They can't have it both ways. Sure a legal eagle could destroy my argument but anyone looking from the outside in on this matter knows that Toyota is screwing owners with this issue by making it possible for a hybrid component to only be covered for 3 years max. It's confusing to look at a warranty pamphlet and see the words Hybrid System it sounds so all encompassing.

 

[nels0300]

In terms of vehicles affected and cost of failure, this is almost equivalent to Hyundai/Kia’s engine failure problem.

Hyundai/Kia now have a lifetime warranty on affected engines.

Toyota needs to do the same with this harness. Might take a class action lawsuit and/or regulator action, but hoping Toyota eventually gets there.