2009 Toyota Fj Cruiser

The FJ Cruiser's ladder frame is susceptible to severe rust and corrosion, particularly in northern states and regions where road salt is used. The frame rails, crossmembers, and rear trailing arm mounts can develop structural rust that compromises vehicle safety. This is a carryover issue from the shared Tacoma/4Runner platform.

Inspect the frame annually for corrosion. Toyota offered a frame rust warranty extension and replacement program for some affected vehicles under a Customer Support Program. Apply a professional rust-preventive undercoating (such as Fluid Film or Krown) annually. Severely rusted frames may require professional repair or plate welding by a certified shop.

The air conditioning compressor on the 4.0L 1GR-FE engine is prone to premature failure, resulting in warm air from the vents. Owners may hear a grinding or squealing noise from the compressor pulley before complete failure. When the compressor seizes, it can shed metal debris throughout the A/C system, contaminating the condenser and expansion valve.

Replace the A/C compressor, receiver-dryer, and expansion valve. If the compressor shed debris, a full system flush of the condenser and lines is required before installing the new compressor. Use only the correct ND-OIL 8 compressor oil and the specified refrigerant charge of R-134a.

The brake booster on the FJ Cruiser can develop an internal diaphragm leak, causing a hard brake pedal that requires excessive force to stop the vehicle. Owners may also hear a hissing sound from behind the dashboard when pressing the brake pedal. The check engine light may illuminate with lean condition codes due to the vacuum leak.

Replace the brake booster assembly. There is no TSB for this specific issue, but it is a well-documented failure on the 2007-2014 FJ Cruiser platform. The master cylinder should be inspected for damage during replacement. Brake booster replacement requires removal of the master cylinder and extensive dashboard disassembly.

The rear differential pinion seal and axle shaft seals are common leak points on the FJ Cruiser, especially on vehicles used for off-roading or towing. Owners notice gear oil drips under the rear axle and may detect a strong gear oil smell. If left unaddressed, fluid loss can lead to differential bearing damage and eventual failure.

Replace the leaking pinion seal or axle shaft seals. Drain and refill the differential with Toyota 75W-90 gear oil. If the pinion flange surface is grooved or worn, a speedi-sleeve repair or flange replacement may be needed to ensure a proper seal. Inspect the differential fluid for metal particles indicating bearing wear.

The evaporative emissions (EVAP) charcoal canister mounted under the vehicle can crack or become damaged from off-road debris impacts, causing a persistent check engine light with EVAP codes P0441 or P0446. A fuel smell near the rear of the vehicle may also be present when the canister is compromised.

Replace the charcoal canister assembly and inspect all EVAP hoses and connections for damage. Relocating the canister with an aftermarket skid plate is recommended for owners who frequently off-road. Toyota does not offer a TSB for this issue, but canister replacement resolves the codes and fuel odor.

Southeast Toyota Distributors, LLC (SET) is recalling certain 2005-2011 4Runner, Highlander, Sequoia, and Sienna, 2005-2010 Avalon and Tundra, 2006-2008 Camry Solara, 2006-2010 Highlander hybrid, 2006-2011 Rav4 and Tacoma, 2007-2010 FJ Cruiser, 2007-2011 Camry hybrid, 2009-2010 Venza, 2010-2012 Prius, 1988-1990 and 2005-2010 Camry, and 1989 and 2009-2010 Corolla vehicles equipped with aftermarket accessory seat heaters with a copper strand heating element. The electrical wiring in the seat heaters may be damaged when the seat cushion is compressed.

If damaged, the copper strand heating element may short circuit, increasing the risk of a fire.

SET will notify owners, and dealers will disconnect the seat heaters, free of charge, and refund the purchase price of the seat heater accessory. The recall began on July 14, 2016. Owners may contact SET customer service at 1-866-405-4226. SET number for this recall is SET16B.

Southeast Toyota Distributors, LLC (SET) is recalling certain model year 2010-2011 Prius and Corolla, 2009-2011 Venza, 2006-2010 Avalon, 2007-2010 FJ Cruiser, 2005-2011 Sienna and Sequoia, 2006-2011 Tacoma 4x2 and 4x4, Camry, Highlander, Tundra 4x2 and 4x4, and 2007-2011 Rav4 and 4Runner. The affected vehicles may experience compression of the seat cushion which may damage the seat heater wiring.

Damage to the seat heater wiring could cause the wires to short, increasing the risk of the seat burning and causing personal injury to the occupant.

SET will notify owners, and dealers will disconnect the heaters with copper strand heating elements and refund the purchase price of the seat heater accessory, free of charge. The recall is expected to began in January 2015. Owners may contact SET customer service at 1-866-405-4226.

Toyota Motor Engineering & Manufacturing (Toyota) is recalling certain model year 2008-2014 FJ Cruiser and Tacoma vehicles equipped with accessory wheels and tires installed by Toyota or dealers prior to the vehicle's first sale. The affected vehicles may list incorrect spare tire size and/or cold tire inflation information on the tire placard. As such, these vehicles fail to comply with Federal Motor Vehicle Safety Standard No. 110, "Tire Selection and Rims for Passenger Cars."

If the spare tire is inflated to the incorrect pressure provided on the placard, tire failure may occur while it is being driven on, increasing the risk of a crash.

For the involved vehicles, overlay stickers to correct the tire placard will either be mailed to owners or provided to dealers for placement over the incorrect information on the placard. The recall is expected to begin in September 2014. Owners may contact Toyota customer service at 1-800-331-4331.

Toyota Motor Corporation (Toyota) is recalling certain model year 2007-2013 FJ Cruiser vehicles manufactured January 25, 2006 through February 23, 2013 and equipped with a Toyota Auxiliary Driving Lamp Kits mounted to the front bumper. These lamp assemblies include 55 watt bulbs and due to this wattage and mounting angle, the combination of the upper beam headlamps plus the auxiliary lamps are too bright and exceed the maximum light output allowed for an upper beam headlamp. Therefore, these vehicles fail to conform to Federal Motor Vehicle Safety Standard No. 108, "Lamps, reflective devices, and associated equipment."

Light intensities above the maximum allowable limit could cause increased glare for oncoming traffic and increase the risk of a crash.

Toyota will notify owners, and dealers will replace the 55 watt bulbs with 35 watt bulbs, free of charge. The recall began on June 6, 2013. Owners may contact Toyota at 1-800-331-4331.

Toyota is recalling certain model year 2007 through 2013 FJ Cruiser passenger vehicles. The retractors for the front driver and passenger seat belts are mounted in the access door (rear door) panels of the vehicle. Due to insufficient strength of the access door panel, cracks may develop in the panel if the access door is repeatedly and forcefully closed over an extended period of time.

If cracks occur in the panel around the lower retractor anchor, the seat belt retractor could become detached, which could increase the risk of injury to an occupant in the event of a crash.

The safety recall began on June 6, 2013. Toyota will mail an interim letter to owners late in April 2013. Remedy notifications to the owners for the repair will begin in late May 2013. Owners may contact Toyota at 1-800-331-4331.

Southeast Toyota Distributors, LLC (SET) is recalling certain models interspersed through model years 2009 through 2013 as follows: model year 2009-2012 Tacoma, 4Runner, Camry, Camry Hybrid, Prius, and RAV4; model year 2009-2010 Avalon, FJ Cruiser, and Highlander Hybrid; model year 2010-2013 model year Corolla, Sienna and Tundra; model year 2009-2013 Highlander and Venza; model year 2012 Prius V; and model year 2010-2012 Sequoia. During modification by SET to include accessories such as leather seat covers, seat heaters or headrest DVD systems, these vehicles may not have had the passenger seat occupant sensing system calibration tested. Without passing the calibration test, the occupant sensing system may not operate as designed.

If the front passenger seat occupant sensing system is out of calibration, the front passenger airbags may not deploy or they may deploy inappropriately for the passenger's size and position. This could increase the risk of personal injury during the event of a vehicle crash necessitating airbag deployment.

Southeast Toyota will notify owners, and dealers will test the sensitivity of the occupant detection sensors, and recalibrate them as necessary. The recall began on March 21, 2013. Owners may contact Southeast Toyota at 1-800-301-6859.

Toyota is recalling certain Toyota Racing Development (TRD) brake kits, P/N PTR09-35070, and TRD High-Performance brake kits, P/N PTR09-35100, installed by Toyota vehicle processing centers and sold by Toyota dealers as an optional accessory for model year 2007 through 2012 Toyota FJ Cruiser vehicles. The subject TRD brake kit is specifically designed for the front wheels of 2007-2012 model year FJ Cruiser vehicles. Due to the shape of the outer brake tube of the brake kit, the clearance between the outer brake tube and a TRD 16 inch 6-spoke alloy wheel is minimal. If wheel balance weights are installed in an incorrect location, there is a possibility that the outer brake tube could be damaged due to interference with the balance weight, and brake fluid could leak from the damaged tube.

If a brake tube becomes damaged and leaks fluid, it may result in increased stopping distances, and in some cases, loss of vehicle front braking performance, which could increase the risk of a crash.

All known owners of 2007-2012 model year FJ Cruiser vehicles will be notified by first class mail. If the vehicle is equipped with one of the TRD brake kits, the brake caliper outer brake tube will be replaced with a newly designed one at no charge. During this service, if necessary, the dealer will make wheel balance adjustments. This remedy will be performed even if the vehicle has original equipment 16 inch or 17 inch wheels or TRD 16 inch Beadlock ring type wheels, which are not affected by the condition, to assure sufficient clearance in the event wheels are changed at a later time. Notification to owners began on December 17, 2012. Owners may contact Toyota Customer Experience Center at 1-800-331-4331.

TOYOTA IS RECALLING CERTAIN MODEL YEAR 2008 THROUGH 2011 FJ CRUISER, LAND CRUISER, TACOMA, SEQUOIA AND TUNDRA VEHICLES FOR FAILING TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 138, "TIRE PRESSURE MONITORING SYSTEM (TPMS)." WHEN FACTORY-INSTALLED WHEELS AND TIRES WERE REPLACED WITH TOYOTA AUTHORIZED ACCESSORY WHEELS AND LT TIRES PRIOR TO FIRST SALE, THE TIRE PRESSURE MONITORING SYSTEMS WERE NOT RE-CALIBRATED CORRECTLY AND THEREFORE DO NOT START ILLUMINATING THE LOW TIRE PRESSURE WARNING TELLTALE AT THE REQUIRED MINIMUM ACTIVATION PRESSURE.

FAILURE TO WARN OF TIRE DEFLATIONS IS A NON-COMPLIANCE WITH FMVSS 138 AND COULD LEAD TO TIRE FAILURE INCREASING THE RISK OF A CRASH.

FOR THE LAND CRUISER, SEQUOIA, TACOMA AND TUNDRA VEHICLES, THE DEALER WILL RE-CALIBRATE THE TIRE PRESSURE MONITORING SYSTEM ON AFFECTED VEHICLES AND INSTALL AN UPDATED TIRE AND LOADING INFORMATION LABEL AT NO CHARGE. FOR THE FJ CRUISER VEHICLES, THE TPMS CANNOT BE RESET SO THE ELECTRONIC CONTROL UNIT (ECU) FOR THE TPMS WILL BE REPLACED. TOYOTA IS CURRENTLY DEVELOPING THE REMEDY ECU. IF AN OWNER IS NOT CERTAIN WHETHER HIS OR HER VEHICLE IS EQUIPPED WITH THESE ACCESSORIES, PLEASE CONTACT ANY TOYOTA DEALER FOR AN INSPECTION AT NO CHARGE. THE SAFETY RECALL BEGAN ON MARCH 31, 2011. OWNERS MAY CONTACT TOYOTA AT 1-800-331-4331.

MARATHON IS RECALLING CERTAIN SEAT COVERS, BRAND SUPERHIDES WITH PART NUMBERS 593, 594, 578, 960, 228, 228-09, 267-08, 333, 625, AND 630, SOLD FOR USE AS AFTERMARKET EQUIPMENT FOR VARIOUS PASSENGER VEHICLES. THESE SEAT COVERS ARE MADE OF HEAVIER THREAD AND ARE NOT COMPATIBLE WITH SEATS CONTAINING SIDE AIRBAGS. THE HEAVIER SEAT COVER COULD INTERFERE WITH FULL DEPLOYMENT OF THE AIRBAG IN THE EVENT OF A CRASH.

AN IMPROPERLY DEPLOYED AIRBAG COULD RESULT IN SERIOUS INJURY.

MARATHON WILL NOTIFY OWNERS OF RECORD AND REPLACE THE SEAT COVER FREE OF CHARGE. THE SAFETY RECALL BEGAN ON SEPTEMBER 14, 2010. OWNERS MAY CONTACT MARATHON AT 1-800-735-2769.

GULF STATES TOYOTA IS RECALLING CERTAIN MODEL YEAR 2005-2010 VEHICLES FOR FAILING TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 110, "TIRE SELECTION AND RIMS." THESE VEHICLES WERE SOLD BETWEEN SEPTEMBER 1, 2005 AND JUNE 2, 2008 WITHOUT THE REQUISITE LOAD CARRYING CAPACITY MODIFICATION LABELS.

THIS DOES NOT MEET THE STANDARD REQUIREMENTS.

DEALERS WILL MAIL TO CONSUMERS THE CORRECTED LABEL OR THE CUSTOMER WILL HAVE THE OPTION FOR DEALERS TO INSTALL THE LABEL FREE OF CHARGE. DEALERS WILL ALSO CORRECT THE OWNER'S MANUAL. THE SAFETY RECALL BEGAN ON MAY 27, 2010. OWNERS MAY CONTACT GULF STATES TOYOTA AT 713-580-3300.

SOUTHEAST TOYOTA IS RECALLING CERTAIN MODEL YEAR 2005-2011 PASSENGER VEHICLES FOR FAILING TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 110, "TIRE SELECTION AND RIMS." THESE VEHICLES WERE SOLD WITHOUT THE REQUISITE LOAD CARRYING CAPACITY MODIFICATION LABELS.

A DRIVER MAY OVERLOAD A VEHICLE WHICH MAY INCREASE THE RISK OF A CRASH.

DEALERS WILL MAIL TO CONSUMERS THE CORRECTED LABEL OR THE CUSTOMER WILL HAVE THE OPTION FOR DEALERS TO INSTALL THE LABEL FREE OF CHARGE. THE SAFETY RECALL BEGAN ON MAY 27, 2010. OWNERS MAY CONTACT SOUTHEAST TOYOTA AT 1-800-301-6859.

TOYOTA IS RECALLING 27,080 MODEL YEAR 2005 THROUGH 2010 PASSENGER CARS BUILT FROM SEPTEMBER 1, 2005 TO MAY 4, 2009. THESE VEHICLES WERE NOT EQUIPPED WITH LOAD CARRYING CAPACITY MODIFICATION LABELS WHICH FAILS TO CONFORM WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 110, "TIRE SELECTION AND RIMS."

INCORRECT LOAD CARRYING CAPACITY MODIFICATION LABELS COULD RESULT IN THE VEHICLE BEING OVERLOADED, INCREASING THE RISK OF A CRASH.

TOYOTA WILL NOTIFY OWNERS AND PROVIDE THEM WITH A NEW, ACCURATE LABEL TO BE INSTALLED OVER THE INACCURATE LABEL FREE OF CHARGE. THE SAFETY RECALL BEGAN ON AUGUST 18, 2009. OWNERS MAY CONTACT TOYOTA AT 1-888-270-9371.