2021 Toyota RAV4 Prime Problems

What owners report

Owners of this model year mainly report two categories of complaints: a large share describe waiting for a remedy for the DC-DC converter recall (23V478000) and for the cold-weather hybrid system recall (23V041000), often noting they have not experienced a failure themselves. Others describe fueling issues where the tank accepts noticeably less than its rated capacity, and occasional brake feel changes over bumps. Many reports arrive at very low mileage, which reflects the young age of the vehicles when filed.

1. 1
   Electrical system

   Recall remedy not yet available (DC-DC converter)

   • 22 complaints (22%)
   • typically at 2.8 yrs old
   • filed 2023–2024

   Many owners report receiving notice of a recall concerning the DC-DC converter and an electrical short-circuit risk, then being told the replacement part was not yet available. Complaints describe months of waiting, repeated calls to the dealer and manufacturer, and frustration that charging or driving continued before a fix was offered. Several owners state they had not experienced an actual failure, while others describe worry about charging in cold weather. Mostly reported within the first few years of ownership, often in late 2023 and early 2024, with many vehicles at low mileage.

   Recall 23V478000Recall 23V041000

   What to check: Ask whether both open recalls have been completed and request the repair paperwork. Confirm with a dealer whether any remedy is still outstanding for the vehicle.

   2 excerpts from owner complaints in NHTSA records

   “RE: RECALL # 23TA07 for 201 Toyota Rav Prime. An interim recall notice was issued a year ago stating We are currently preparing a remedy. We will notify you again when remedy is available. Toyota Corporate has no information when this recall will be addressed. I paid over $5000 to get a plug- in hybrid and now cannot use the plug- in feature when temperature is below 40 degrees in the winter. The car is useless as designed.”

   NHTSA complaint #11584903, filed 2024-04

   “I received the recall letter (23TB07) 7/12/2023 stating that my RAV4 had potential to start on fire. I have called several times and been told that on this date (11/2/2023), almost 5 months later, there is still no remedy and that there is no projected date for remedy.”

   NHTSA complaint #11553255, filed 2023-11
2. 2
   Brakes

   Unintended acceleration at low speed while braking

   • 15 complaints (15%)
   • median 9,300 mi at 0.4 yrs old (1 states mileage, few)
   • 7 mention a crash, fire or injury
   • filed 2021–2025

   A number of owners describe the vehicle surging forward while they were braking at low speed, such as pulling into a parking space or driveway, and in some cases striking another vehicle or a structure. Complaints mention no warning light or airbag deployment at the time, and that dealers inspected the car without identifying a cause. Other owners describe the opposite: brief delays in acceleration when leaving a stop. Reported in varied conditions at low speed, with no clear mileage pattern in the complaints.

   Recall 23V041000

   What to check: Drive the car at parking-lot speeds and check that accelerator and brake response feels consistent; ask whether the hybrid control software recall has been completed.

   2 excerpts from owner complaints in NHTSA records

   “I was pulling into a parking space at a slow speed and breaking when my car accelerated violently and caused me to go across a median and strike another parked vehicle. Police came and did a report. I took my car right away to dealer and they had me take it to their collision shop to be repaired. They said they would try to find the unintended acceleration problem after it was repaired. No warning lights or airbags.”

   NHTSA complaint #11563605, filed 2024-01

   “When pulling into a parking spot at less than 5 mph the car accelerated violently and couldn't be stopped while braking. A marble or granite barrier stopped the my car preventing me from going into a shallow ravine and potential on coming traffic. There have been multiple safety recalls on the braking system on the car and each have been executed in a timely fashion. I cannot determine if warning lights went off at the time due to how quickly the issue happened”

   NHTSA complaint #11534494, filed 2023-07
3. 3
   Brakes

   Brake pedal feel changes over bumps or wet roads

   • 11 complaints (11%)
   • median 9,300 mi at 0.4 yrs old (1 states mileage, few)
   • 3 mention a crash, fire or injury
   • filed 2021–2025

   Owners describe a momentary loss of braking or a surging, grinding feel when braking over rough pavement, potholes, or wet roads, sometimes with an orange warning light. Complaints say the pedal can feel different for a second before normal braking returns, and that dealers were often unable to reproduce the condition. Some owners also report brake rotors showing pitting or scoring at relatively low mileage. Reported from a few thousand miles up through higher mileage, typically tied to bumps, wet pavement, or low-speed stops.

   What to check: Test the brakes over uneven pavement and on wet surfaces during a test drive, and ask whether any brake work or software updates have been performed.

   2 excerpts from owner complaints in NHTSA records

   “I am experiencing inconsistent brake feel after ABS actuation during slow and steady application of the brakes on rough or slick road surfaces. Stopping distances are increased compared with my expectation for a given pedal force. Please note that the 2010 Toyota prius had a similar issue, and a recall was issued under NHTSA campaign 10v039000.”

   NHTSA complaint #11395499, filed 2021-02, 9,300 miles

   “When braking and hitting a slight bump in the road or on a wet road it actually like my car is accelerating, seems to be a possible issue with the regenerative brake system and the antilock brake system software working together. Luckily i have not hit anyone, but this is a major safety flaw. Has happened multiple times.”

   NHTSA complaint #11547682, filed 2023-10
4. 4
   Fuel system

   Fuel tank accepts less than rated capacity

   • 8 complaints (8%)
   • median 804 mi at 0.4 yrs old (2 state mileage, few)
   • filed 2021–2022

   Owners report that refueling stops well short of the tank's rated capacity, with the gauge showing full or the nozzle clicking off early, and in some cases fuel spilling. Complaints describe range estimates that seem low after a fill and frustration that dealers described the behavior as normal. Some mention a check engine light or fuel gauge readings that do not match the actual fuel level. Often reported in the first few thousand miles, including on the very first fill-ups.

   What to check: Note how much fuel the tank takes from near-empty and whether the gauge matches; ask the seller if this has been raised with a dealer.

   2 excerpts from owner complaints in NHTSA records

   “Car has 750 miles from new. Fuel guage display 3/4 full when tank is actually full.. Causes overfilling and lack of trust in guage reading. Also causes charcoal filter to fill with gas. Causing it to fail. In addition check engine light to display generating numerous faults comes. All require immediate dealer attention. No drive condition.”

   NHTSA complaint #11388815, filed 2021-01, 700 miles

   “During its first fuel tank fill-up (at 909 miles, on 3/14/2021), new 2021 RAV4 PRIME se fuel tank accepted less than the expected amount of gasoline. Starting at near-empty, only nine (9) gallons was accepted. At the second fill-up (on 3/22/2021), only four gallons could be added, and the fuel nozzle was ejected from the tank, spilling gas. Second attempt could not add any more gas.”

   NHTSA complaint #11405264, filed 2021-03, 909 miles
5. 5
   Other or unknown

   Sunroof glass shattering while driving

   • 7 complaints (7%)
   • typically at 2.1 yrs old
   • filed 2022–2026

   Owners report hearing a loud bang and finding the sunroof glass shattered, with glass falling into the cabin, while driving on the highway with nothing overhead. Complaints describe no visible impact point on the glass and say the dealer or manufacturer suggested an external cause. Several owners say the noise startled them enough to affect control of the car. Reported at varied mileages, typically while driving at highway speed.

   What to check: Inspect the sunroof glass closely for chips, edge damage, or prior replacement, and ask whether the panel has ever been replaced.

   2 excerpts from owner complaints in NHTSA records

   “Husband and I bought our 2021 RAV4 Prime from Toyota last Jan, brand new and I’ve had no complaints. On Dec 27, 2022 we were running errands and all of a sudden our sunroof EXPLODED. It sounded like a gun went off right in between us and then showered us with glass residue. There were no cars around us so we immediately pull into a parking lot and notice the glass exploded up and out. …”

   NHTSA complaint #11499197, filed 2022-12

   “I was driving my 2021 Toyota Rav4 Prime on the freeway. As I was exiting the freeway there was a LOUD explosion in my car that scared the hell out of my friend and I, almost causing me to get into an accident. I pulled over and got out to see what happened. As I walked around the car I checked the tires, which were fine. I did not see anything (it was dark). I could not see the roof (I am short) and the moonroof shade was closed. …”

   NHTSA complaint #11489696, filed 2022-10

Buying note. Check that open recalls for this model year have been completed and get the paperwork, and budget time to verify fueling behavior and brake feel on a test drive. Most reports in the sample concern recall timing and fuel gauge behavior rather than breakdowns, so service records matter more than mileage alone.

Summary written with AI from a sample of 60 NHTSA complaints for this model year (picked at random, with complaints that state a mileage and recent ones taken first), then checked automatically against the source records. Where a problem shows a complaint count, every complaint for this model year was matched with fixed keyword rules (written with AI and tested against the sample), and the mileage, age and repair figures are calculated from those complaints; owners' figures are as stated, not verified. Other counts refer to the sample. The excerpts come from NHTSA's public complaint records and are unverified; capitalisation is normalised, NHTSA staff notes are removed, and shortened text ends with “…”. Something wrong? Request a correction.