Certain transistors on the control boards in some vehicles were inadequately soldered and could be damaged from heat caused by a large current flow during high-load driving.

TORRANCE, Calif.— Toyota Motor Sales, USA, Inc., said on 29 June 2011 that it will conduct a voluntary safety recall involving about 45,500 Highlander Hybrid and 36,700 Lexus RX 400h vehicles sold in the U.S. No other Toyota or Lexus vehicles are involved.

The Intelligent Power Module (IPM) located inside the Hybrid System Inverter contains a control board with transistors. Certain transistors on the control boards in some of the subject vehicles were inadequately soldered and could be damaged from heat caused by a large current flow during high-load driving.

If this were to occur, various warning lamps will illuminate on the instrument panel. In most cases the vehicle will enter a fail-safe driving mode, resulting in reduced power in which the vehicle can still be driven for short distances. In limited instances, the power supply circuit fuse could blow when the transistor is damaged. If the fuse blows, the hybrid system will stop and the vehicle will coast to a stop.

Toyota is working on obtaining the necessary replacement parts. Once the replacement parts are available, it will notify owners. Meanwhile, owners of the involved vehicles will be notified of the recall by first class mail in mid-July 2011.

Once the replacement parts have been produced in sufficient quantities, Toyota will send a second owner-notification by first class mail advising owners to make an appointment with an authorized Toyota dealer to have the IPM inspected and if necessary replaced at no charge.

Detailed information and answers to questions are available to customers at www.toyota.com/recall and the Toyota Customer Experience Center, (800) 331-433, or www.lexus.com/recall and Lexus Customer Satisfaction, (800) 255-3987.

Source: Autoblog Green