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Toyota recall: Engineers come up with pedal fix

By | February 1, 2010, 5:18 AM PST

Toyota said Monday that its engineers have cooked up “a precision-cut steel reinforcement bar” that will fix the sticking gas pedal problem that forced the company to suspend sales of a bevy of popular vehicles.

With its reputation on the line, Toyota’s fix is fairly simple on the surface, but now the company has to deploy the solution in the field. Toyota’s recall issue comes at the intersection of numerous business issues ranging from tracking a global supply chain to customer communications to managing partners.

In a statement, Toyota said it has “developed and rigorously tested a solution that involves reinforcing the pedal assembly in a manner that eliminates the excess friction that has caused the pedals to stick in rare instances.”

If you recall, Toyota recalled 2.3 million vehicles due to the sticking gas pedal on Jan. 21. On Jan. 26, Toyota suspended sales of eight models including popular cars like the Camry, Corolla and RAV4. That suspension will continue through the week of Feb. 1.

Toyota added that it will keep dealerships open for extended hours—including 24 hours at some locations—to fix the pedal. Accelerator pedals were getting stuck in an open position.

Here’s a look at the fix in detail:

A precision-cut steel reinforcement bar will be installed into the assembly that will reduce the surface tension between the friction shoe and the adjoining surface.  With this reinforcement in place, the excess friction that can cause the pedal to stick is eliminated.  The company has confirmed the effectiveness of the newly reinforced pedals through rigorous testing on pedal assemblies that had previously shown a tendency to stick.

Jim Lentz, president and chief operating officer of Toyota Motor Sales, said:

Stopping production is never an easy decision, but we are 100% confident it was the right decision.  We know what’s causing the sticking accelerator pedals, and we know what we have to do to fix it.  We also know it is most important to fix this problem in the cars on the road. We are focused on making this recall as simple and trouble-free as possible, and will work day and night with our dealers to fix recalled vehicles quickly.

Contrary to published reports, Lentz said on NBC’s Today show that the gas pedal issue was not related to faulty electronics.

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Larry Dignan

About Larry Dignan

Larry Dignan is the editor-in-chief of SmartPlanet.

Larry Dignan

Larry Dignan

Editor-in-Chief

Larry Dignan is editor-in-chief of SmartPlanet and ZDNet. He is also editorial director of TechRepublic. Previously, he was an editor at eWeek, Baseline and CNET News. He has written for WallStreetWeek.com, Inter@ctive Week, New York Times and Financial Planning. He holds degrees from the Columbia University Graduate School of Journalism and the University of Delaware. He is based in New York but resides in Pennsylvania.

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Larry Dignan

Larry Dignan
Larry Dignan does not hold any investments in the companies he covers.
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0 Votes
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RE: Toyota recall: Engineers come up with pedal fix
Something's not quite right with this whole affair. Petitions to NHTSA show the problem has existed long before CTS started making the pedal assembly and CTS has never made pedals for Lexus (NHTSA reports show the problem exists on Lexus too).
I suspect we haven't heard the last about this issue.
Posted by netsysmgr@...
1st Feb 2010
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Another bogus fix by Toyota
This is another bogus fix by Toyota. First they claimed it was
"floor mats" -- when the off-duty California highway patrol
officer's car was going 120mph and they couldn't stop it. A family
member made a 911 call while the incident was occuring. He was
standing on the brakes and the car was still going 120mph. They all
died. Toyota still said "floor mats".

Then in December a 2008 Avalon went into a pond, killing 4 people,
with no signs of braking. Toyota said floor mats until the floor
mats were found in the trunk. The owner had removed them. Now they
are saying "gas pedal" -- no it's either electronic sensors or
faulty software apparently written by Microsoft rejects. happy
Software crashes every one in a while and causes the car to go full
throttle.

The other fix they were talking about, making the gas pedal software
cut off then the brakes are applied is a no-brainer that should have
been done YEARS ago. Just like when your cruise control shuts off
when you tap the brakes. In fact this whole situation is VERY
reminiscent of a berserk cruise control that can't be shut off. I
know it has nothing to do with cruise control, but the similarities
is what points to software bugs.
Posted by ChazzMatt
1st Feb 2010
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RE: Toyota recall: Engineers come up with pedal fix
It looks as though this is a problem especially if you push the pedal all the way down forcefully. This is the first I have seen a diagram of the fix. I have a 2009 Corolla and have not had any issues. I imagine this is what most people are experiencing, nothing. Glade the media has whipped up everyone into a frenzy.That's what they do best.
Posted by jscott418
1st Feb 2010
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RE: Toyota recall: Engineers come up with pedal fix
I want to know too why a highway patrol officer did not think to just shut the car off? They had time to make a cell phone call but nobody could suggest to just put it in neutral or turn off the ignition. That is what's sad. Some of these people had time to react and they failed to do so.
Posted by jscott418
1st Feb 2010
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RE: Toyota recall: Engineers come up with pedal fix
@ChazzMatt: the floor mats are a separate issue. I received a letter on
the floor mats for my Tacoma but I am not using the stock ones anyway.
The floor mat problem seems more caused by the length of the
accelerator pedal catching the mat.

As for the accelerator pedal, though the actual occurance is still
rare, a smart driver would be able to handle this if it happened like
@jscott418 noted. Click the ignition off, and merge off the road. Since
I dont know the exact details of the faulty accelerators I cannot say
whether or not the fix looks correct but I commend Toyota for not being
totally ignorant on this issue and notifying customers
Posted by bpunk88
1st Feb 2010
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Problem not electronics, but fail safe design ignored
"Contrary to published reports, Lentz said on NBC?s Today show that the gas pedal issue was not related to faulty electronics."

The sticking gas pedal may not be related to electronics. But the fact that owners who experienced it were not intuitively able to shut the car down is an absolute failure of fail safe design and programming.

First, pressing the brake should electronically kill the fly-by-wire throttle system. The only reasonable use of both pedals at the same time is power braking for the greatest off the line acceleration. This is damaging to the car, and only helps car enthusiast magazines post higher than practical acceleration times. If Toyota wanted a "maintenance" mode that removes many fail safes and has to be selected on every engine start, to allow this type of activity is an option, but it shouldn't be available by default.

For the victims that experienced run away cars that were unable to turn the car off because of push button ignition or electronically selected transmission, these safeguards were also poorly designed.

Requiring a 2 second push of the ignition button to turn off the car was ignorant. With the car in motion, more than 2 quick pushes of the button should have been interpreted as a panicked driver. That should have sounded an alarm to warn of an impending shutdown, turned off the ignition after 2 seconds, and left all accessories powered up. If pressed again after the engine stopped, it should have immediately restarted, to mitigate the concern of an unintended shutdown.

Finally shifting from drive to neutral with the car in motion should not have been prevented. If shifted to neutral, the car should have flashed all of the transmission indicator lights on the dashboard, and after 5 seconds if the shifter was not returned to drive, it should have physically shifted the transmission to neutral to coast down.

It was poor programming and user design by Toyota that was an extenuating factor leading to deaths and injuries of a few of their customers.
Posted by colinnwn
1st Feb 2010
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Toyota Quality never was that great to begin with...
Toyota won quality kudo's 20 years ago, not because they were better, but because they built cars with NOTHING ON THEM!!! So, basically nothing could break. Today, Toyota along with all other makers build basically the same level of cars. And, they all perform identical in quality checks.

Where the difference is that I find is in the repair of vehicles. I repair a lot of car problems myself. I also do some work on family vehicles, and occasional for friends. I always cringe when I have to work on a Toyota owned by one of these folks. They are so hard and expensive to work on. And, yes they need as much work as a good Ford or Chevy. But at least the Ford or Chevy is 10 times easier to work on. And, usually much cheaper.

So, for my money, I'll buy American cars. At least more of my money will stay here in the US creating more jobs for our guys. AND it'll make my life easier when I need to work on something on one of these cars. Don't forget, that building a car is only 50% of the profit. There's also the engineering and support costs for each car built. For Japanese, the other 50% goes overseas for the engineering and support of that vehicle! Keep more of the profit here in the US, buy wisely.
Posted by Narg
1st Feb 2010
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RE: Toyota recall: Engineers come up with pedal fix
As a Toyota owner, I could see this coming a mile away. From my own experience, Toyota will do everything in its power not to assist a customer when it comes to repairs. It,s policy has been the dealer is always right and the customer is always wrong. Will not assist you at all when dealing with an underhanded dealer. They wash their hands and you are on your own. My next car will not be a Toyota or Lexus, you can bet on that!!!!
Posted by rbuckne@...
1st Feb 2010
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the uncontrolled acceleration may have multiple causes
I keep hearing about runaway Toyota issue without a sticking pedal or floor mats in the way. I have long refused to purchase a Toyota after realizing that most use electronic controls for acceleration control instead of a cable or other mechanical solution gas control.

Not unusual for Toyota to have issues with reliability. Remember those rail type automatic seat belts? Which fail as the vehicle gets older--I know this is true because it happened to me, costing me $25000 in hospitalization and a broken sternum because I hit the steering column thinking the seat belts were working. Same issue, relying on iffy solutions when people's lives are on the line.

I will never buy a Toyota
Posted by WinnebagoBoy
1st Feb 2010
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Unknown Dangers
I heard about the car pedal recall but had no idea it affected my NON toyota truck good thing I found more info here http://www.carpedalrecall.com
searched for my make, model, year and found my Ford truck had been recalled so look out! it could save a life maybe yours

don't understand, what the car pedal recall is about?
just watch this video
http://www.youtube.com/watch?v=03m7fmnhO0I
after you watch it repsot this it could save lives


this is a video showing how to stop a out of control car.
Might answer questions for all those who say just turn off the car or hit the brakes , on newer car it is not that easy watch
http://www.youtube.com/watch?v=KoIIT0WJS4s
Posted by wwide408
1st Feb 2010
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RE: Toyota recall: Engineers come up with pedal fix
@Narg

In my experience Nissan and Toyota cars are as easy or easier to work on as modern American cars. I've seen some really stupid design decisions as far as future serviceability from both American and Japaneses companies.

Both Nissan and Toyota have design centers and manufacturing plants in the US as well as Japan. Some American cars are designed in Europe (though most in America), and many are built in Mexico or Canada. The argument in general that an American car company provides more benefits to American citizens is a misguided one. Though we could more truthfully argue about specific models when we can discuss where it was engineered and built.
Posted by colinnwn
1st Feb 2010
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Toyota has been using cheapest parts as per their dealer's service manager
I have been a loyal Toyota owner for 18 years, one after the other. I am not surprised that their policy came back and bite them. My last Camry by 50,000 miles ate approximately 6900 worth or repairs (suspension, water pump...etc). When I asked why, the service person admitted that Toyota has been using the cheapest parts they can get. They have been doing this to maximize their profit and keep prices competitive. He stated that it is the name that sells not the quality. Some parts are not safety issue and are not recalled despite the fact that Toyota has changed the part number and manufacturer if the car comes in for repair. If the customer is lucky, the part will fail before the warranty expires (which they are also cheated on since the odometer over-read the miles). This drove the quality down. The only Toyota's that has no parts issues are the 4-Runner and the Yaris (totally made in Japan)
Posted by mke@...
1st Feb 2010
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RE: Toyota recall: Engineers come up with pedal fix
From what I can discern, the "excessive friction" would not occir unless the pedal was fully depressed (floored). How many people over the age of 21 ever feel a NEED to ever do that?

(I know I could answer my own question here, but I'd be accused of being sexist, racist and SUVist.)
Posted by parabellus-a-um
4th Feb 2010
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RE: Toyota recall: Engineers come up with pedal fix
I have a 2009 Camry that I take excellent care for and I have only put in less than 3,000 miles. Even when we first bought it, we always thought that there were something wrong with the gas pedal because when we release it it would actually accelerate a little before slowing down. Anyways, I took it in for the "Pedal" recall couple of days ago and they fixed the problem and the gas pedal work great (the way it was supposed to bein with). Now, I noticed that they also cut-off a big chunk of my carpet around the area which I'm a little ticked-off about because I think it looks ugly and butchered. Anyone else have the same problem?
Posted by bernardo2
8th Feb 2010
0 Votes
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RE: Toyota recall: Engineers come up with pedal fix
Even when we first bought it, we always thought that there were something wrong with the gas pedal because when we release it it would actually accelerate a little before slowing down. Anyways, I took it in for the "Pedal" recall couple of days ago and they fixed the problem and the gas pedal work great (the way it was supposed to bein with). Now, I noticed that they also cut-off a big chunk of my carpet around the area which I'm a little ticked-off about because it's butcherd and ugly. Anyone else have the same problem?
Posted by bernardo2
8th Feb 2010
0 Votes
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RE: Toyota recall: Engineers come up with pedal fix
I have a 2009 Camry with less than 3,00o miles. I take great care of my car. Even when we first bought it, we always thought that there were something wrong with the gas pedal because when we release it it would actually accelerate a little before slowing down. Anyways, I took it in for the "Pedal" recall couple of days ago and they fixed the problem and the gas pedal work great (the way it was supposed to bein with). Now, I noticed that they also cut-off a big chunk of my carpet around the area which I'm a little ticked-off about
Posted by bernardo2
8th Feb 2010
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RE: Toyota recall: Engineers come up with pedal fix
i think the problem is not mech or electrical but caused by emi this could be eliminated by better grounding and shielding of the accel contol signals
and maybe some farite on the main wiring harness to reduce the stray magnetic interferance caused by the alternator, electric pwr steering motor, fans and any other motor under the hood
Posted by plcfox
7th Apr 2010
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