Transport Canada uncovers “potentially dangerous defect” in Toyota RAV4 models; recalls 150,000 vehicles

Transport Canada has issued an immediate recall for nearly 150,000 Toyota RAV4 models, after finding that rear seatbelts may sever in a crash.

In a statement on Thursday, Transport Canada said that its research engineers and investigators have uncovered a potentially dangerous defect in 2006 to 2012 Toyota RAV4 models. In a severe frontal crash, Transport Canada reported, “contact with the steel structure in the seat may cause the rear seat belt to be cut.”

Nearly 150,000 RAV4s in Canada are being immediately recalled by Toyota to address the issue; it is estimated that over 2.7 million RAV4s may be affected globally by this issue. Other models are unaffected as they use a different seat structure.

The department found the problem after reconstructing a fatal crash involving a 2011 RAV4 in Canada. The case attracted the department’s interest after the front occupants survived the frontal crash, but the rear passengers didn’t. The replicated crash used a RAV4, crash dummies similar in weight to the actual passengers, as well as an impact speed and crash angle that aligned with the fatal crash. During the test, both rear seatbelts severed and both crash dummies sustained potentially deadly injuries.

Transport Canada presented its findings to Toyota immediately once its investigation was complete, the statement said. Toyota subsequently investigated, confirmed the problem, launched a recall on Wednesday, and will install seat flange covers to correct the seatbelt defect, the department reported.

Transport Canada will monitor this recall to ensure Toyota addresses the issue as quickly as possible. Affected owners are asked to contact their Toyota dealers to schedule a time to have the defect repair work completed.

“This is more than just a case of Transport Canada finding a safety problem and doing a thorough investigation,” said Marc Garneau, Minister of Transport, in the statement. “These findings have a real-world impact – and it’s measured in human life. As a result of the department’s investigation into this safety issue, lives will be saved in Canada and around the world. These findings underscore the importance of our crash test and safety oversight programs.”

Each year, the department crashes (and destroys) approximately 50 vehicles at its testing facility in Blainville, Que., which is managed by PMG Technologies.