A Small Welding Error Became a Major Issue for Toyota’s Sienna | Carscoops
A setting on the welding machine used for attaching these seats was incorrect during production.
17 hours ago
by Stephen Rivers
The recall affects all 2025 Sienna Hybrids manufactured between January and July 2025.
Faulty welds on the second-row seat rails may jeopardize crash safety.
Dealers will begin replacing the affected seat rails at no cost starting this December.
Safety is a primary consideration for minivan buyers, as these vehicles are meant to transport families, friends, and a variety of passengers, often with the most crucial ones seated in the second or third row.
According to Toyota, over 50,000 Sienna Hybrid minivans from the 2025 model year could be at risk. The incorrect setting on a welding machine could be responsible for weakened structural integrity in the event of a crash.
Documents submitted to the NHTSA link the issue to Toyota Boshoku Kentucky in Harrodsburg, KY, where the welding machine was improperly calibrated during production.
This mistake occurred while some second-row seat rails were being assembled, potentially leading to incomplete weld penetration. Consequently, the affected seats might not satisfy safety standards in a collision.
The problem was identified during internal testing this summer when a prototype seat did not pass company standards. Subsequent investigations validated the concerns, revealing that some seat rails could lose strength upon impact.
Although this issue does not strictly violate federal safety standards, Toyota has opted to initiate a recall voluntarily for the sake of safety. The company has stated that it is unaware of any warranty claims or field reports related to this matter.
The issue exclusively involves Sienna Hybrids manufactured between January 14 and July 24, 2025, and does not extend to any other two or three-row models from Toyota or Lexus.
Owners should expect to receive official notifications between November 21 and December 6 of this year. Dealers will replace the seat rails in all 54,631 affected vehicles at no cost to the owners.
Toyota has informed dealers promptly, with recall operations logged under campaign codes 25TB12 and 25TA12. Those wishing to verify if their vehicle is affected can check by entering their VIN at NHTSA.gov or by contacting their local dealership.
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A Small Welding Error Became a Major Issue for Toyota’s Sienna | Carscoops
A setting on the welding machine used to attach these seats was incorrect during the production process.