Toyota BZ4x and Subaru Solterra resume production with fix to stop wheels falling off

UPDATE: Toyota BZ4x and Subaru Solterra resume production after fears of wheel loss

The 2023 Toyota BZ4x and 2023 Subaru Solterra electric SUV twins will resume production later this month.

It comes more than three months after a joint recall was issued following concerns the wheels could loosen and fall off, and manufacturing in Japan was halted (full details below).

The issue affected more than 4000 units globally – spilt between approximately 2700 Toyota BZ4x and 1600 Subaru Solterra vehicles – just eight weeks after the vehicles went on sale.

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According to industry journal Automotive News, the issue stemmed from Toyota underestimating the instantaneous torque of an electric motor, combined with the extra weight of a battery pack.

It is claimed Toyota was made aware of the issue following a report from Taiwan in late May, followed by two instances in the United States.

The report states the hub bolts attaching the wheels could become loose due to vigorous driving, such as "turning sharply or braking aggressively".

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“It is embarrassing to say that we had done various assessments, but we couldn’t detect this problem because we didn’t conduct the assessments based on a premise that the quality of wheels would be so off in the assessment process,” said Toyota's chief technology officer, Masahiko Maeda.

“We will respond firmly to regain trust in the safety of Toyota vehicles.”

To fix the issue, engineers have reportedly added a washer to the hub bolts.

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The brand has also improved the friction of the wheel surface, which was initially "too rough with wide variances in processing quality."

While it has yet to commence production, the issue also affected the related Lexus RZ electric SUV.

Both the Toyota BZ4x and Subaru Solterra are expected to arrive in Australia in 2023, with pricing and final details to be announced closer to launch.

Jordan Hickey

The story to here

August 8: Suffering BZ4x owners can sell their cars back to Toyota

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Toyota of America has offered to buy back the BZ4x EVs it has already sold, in response to a delay in resolving a fault that could see its wheels come loose and separate from the vehicle.

Owners affected by the risk had been notified in June and were advised to not drive their cars until a solution was found – a 'caution' message which ran counter to the usual type of recall that would normally see owners invited to return to their dealership for an immediate repair action.

Now, months later, Toyota has yet to arrive at a solution for the issue, moving the company to give owners the option to sell their vehicle back – although it's unclear whether they will be fully reimbursed.

To Toyota's credit, the company has provided a loan vehicle to each affected owner at no cost, while also reimbursing all fuel costs. The company has also provided a credit of US$5000 towards loan or lease payments.

In its communication to owners, Toyota said: "The terms for the repurchase may vary, depending on your state and particular circumstances".

The full letter sent to owners is posted below, as shared by an owner on social media website Reddit.

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Hat tip to CarScoops for this story

June 24: Toyota and Subaru recall new EVs over risk of wheels coming loose

Japanese manufacturers Toyota and Subaru have been forced to recall their jointly-developed BZ4x and Solterra electric vehicles only a handful of months after launching.

According to Reuters, both electric vehicles have been recalled due to a risk of the wheels coming loose and falling off, affecting more than 5000 units worldwide.

The Japanese Government's safety regulator has said sharp turns and sudden braking could cause a hub bolt to become loose, with drivers urged to stop using their vehicles until a permanent fix is worked out.

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For the Toyota BZ4x – the manufacturer's first dedicated EV – roughly 2700 examples have been recalled with 2200 of those units in Europe, 260 in the United States, 20 in Canada and 110 in its local Japan.

Around 2600 units of the Subaru Solterra have been impacted by the recall, but it's worth noting neither model is available yet in Australia, although both are slated to hit the local market next year.

Toyota has said its BZ4x will come to Australia "sometime" in 2023, potentially allowing Subaru to introduce the Solterra first with a planned mid-2023 launch date.