2023 TOYOTA BZ4X Complaints

While driving on the highway under normal conditions with no road hazards present, the engine under cover (part #51441-42210) detached from my vehicle and the bumper clips broke, causing both the under cover and bumper to become damaged and requiring replacement. There was no collision, no debris, no pothole, or any other road hazard involved. The failure occurred solely under routine highway driving conditions. Upon taking the vehicle to my Toyota dealership, the service team acknowledged this is a known and recurring issue with the bZ4X model. Research and owner forums confirm multiple 2023 bZ4X owners have experienced the identical failure — undercarriage cover and bumper detachment under normal driving and rain conditions. Toyota dealers have repeatedly told affected owners ‘this happens all the time,’ yet Toyota refuses to cover repairs under warranty, claiming it is not a manufacturing defect. I believe this represents a systematic design or manufacturing defect in the 2023 Toyota bZ4X. The undercarriage cover and bumper mounting system fails under normal driving conditions, which poses a safety risk to the driver and other vehicles on the road. I am requesting a formal investigation into this issue and urge NHTSA to consider a recall to protect other bZ4X owners.

The contact owns a 2023 Toyota BZ4X. The contact stated that the vehicle was awaiting a recall repair. The dealer informed the contact that the electrical HVAC compressor needed to be replaced as part of the recall repair; however, the part was on back order. The vehicle was taken to the dealer, but the recall repair was not completed. The manufacturer was notified of the failure. The approximate failure mileage was 117,000.

The contact owns a 2023 Toyota BZ4X. The contact had attempted to use the defroster; however, the blower was not blowing hot air onto the windshield. The contact had received notification of NHTSA Campaign Number: 25V577000 (Visibility); however, when the dealer was contacted to schedule a recall repair, the contact was informed that the part to do the recall repair was on national back order. The contact called another dealer and the manufacturer, and was informed by both that the part was on national back order. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The failure mileage was approximately 55,000.

The contact owns a 2023 Toyota BZ4X equipped with Goodyear Tires, Tire Line: Electric Drive 2, Tire Size: 215/50/R20, DOT Number: (N/A). The contact stated that while driving at various speeds above 50 MPH, the vehicle experienced severe shaking and abnormal vibration. The vehicle was taken to the local service center who determined that the foam pad inside the tire had malfunctioned. The foam was replaced, and the tires were balanced, but later the same failure reoccurred on the rear passenger’s side tire. The vehicle was taken to the local dealer for repair. No further information was available. The manufacturer was not notified of the failure. The failure mileage was unknown. The VIN was not available.

Premature and abnormal tire wear on my 2023 Toyota bZ4X, confirmed by two independent tire shops, despite consistent Toyota dealer maintenance every 6,000 miles. Beaverton Toyota dealer dismissed the condition as “normal,” but both [XXX] and Discount Tire documented unsafe tire wear caused by alignment. --- Details of Problem: Vehicle serviced exclusively at Toyota dealer (Beaverton Toyota, OR) every 6,000 miles, with multipoint inspections and rotations. On 9/22/25, Toyota dealer inspected the vehicle and reported that alignment and tires were “normal.” On 9/25/25, [XXX] inspected the vehicle and documented severe outside shoulder wear on the right-side tires. They recommended immediate tire replacement for safety. Alignment was also adjusted at that time to bring values into balance (report attached). On 9/27/25, Discount Tire replaced all four tires at 27,562 miles. Their written notes confirm edges were worn on all four tires due to alignment (right side more prominent). They declared the tires unsafe for continued use and recommended full replacement. Safety Concern: This abnormal alignment-related wear created unsafe driving conditions well before the rated tire life (55,000 miles). Uneven edge wear and shoulder failure increase the risk of blowouts, hydroplaning, or sudden loss of control. Attachments available: Toyota dealer report stating “normal” Les Schwab alignment printout and written safety note Discount Tire invoice with technician safety comments Tire photos (all four corners) Full Toyota dealer service history INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

UNKNOWN , 11/26/2024 car in garage would not start, car was tow to Toyota and Toyota replaced the battery. then on 02/06/2025 vehicle was in garage and would not start and vehicle was tow again to Toyota dealer. Where dealer replaced 12 volt battery at 5,283 miles. And told us to put a battery charger on the battery.

I drove the car at 40mph through about 2 inches of standing water. This caused the undercarriage splash plate to become loose. It has not fallen off, but it will need to be repaired. The streets sometimes flood and none of the cars I’ve owned ever had this happen.

AC Compressor. The dealer is saying I need to repair the AC compressor. When this happened my heater and mileage weren't showing and a lot of message errors were showing.

I am writing to register our complaint and urgently request your support in resolving a serious health issue related to what we believe is a factory defect with the Toyota BZ4. Timeline of events: In April 2023, I purchased a brand new BZ4 from the Downtown Oakland Toyota dealership. In July 2024, I noticed a foul smell in the car coming from the air conditioning vents. The car was difficult to drive in due to the severity of the smell. On September 11, 2024, we took the BZ4 to the dealer for maintenance and asked for them to look into the foul smell. The dealer reported they were unable to find the cause of the odor. They offered us a car fragrance. The odor continued to be overwhelming in nature. On [XXX] we inspected the car and removed the floor mats. We discovered the undersides of both left and right front floor mats were covered in mold. The floor carpets were soaking wet with water. Both the mats and carpets smelled very badly. On October 31, 2024, we filed a customer service complaint with Toyota. On November 1, 2024, Daniel at Downtown Oakland Toyota responded that the dealer had found a spider web which had blocked the tube, causing the air conditioning system to be blocked. This caused the blocking of the HVAC tube and the water to pool and mold. I am concerned for several reasons: Toyota sold me a car which, according to them, can have one of its major operating systems (HVAC) taken down by a mere spider web. This is irresponsible and negligent design and the company should be liable for the defect in manufacturing. The car is less than two years old, was purchased new and has been driven for just 11,000 miles and is well within the warranty period. It’s shocking to us that Toyota has refused to repair this defect which we believe to be their responsibility as it falls under a design flaw. A safely designed HVAC system should be able to resist the presence of a tiny spider. The Toyota service staff should be made aware of this defect INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATI

On [XXX] I was involved in a collision with another vehicle on [XXX] , while driving my 2023 Toyota bZ4X. Despite the impact's severity, the airbags in my vehicle did not deploy, even though the other vehicle’s airbags did, suggesting that the impact was sufficient to trigger airbag deployment in similar conditions. After the accident, the Toyota app displayed a warning message indicating that the airbags required inspection, raising concerns about a potential malfunction in the airbag system. The failure of the airbags to deploy posed a significant risk to my safety, as the airbags are a critical safety feature designed to reduce injury in collisions. The vehicle has not yet been inspected by Toyota or a certified service center to determine the cause of the airbag failure. Prior to the collision, there were no visible warning lights or error messages on the dashboard indicating any issues with the airbag system. The vehicle is available for inspection upon request. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)