Recall 16V577 affects 425 2010-2015 Toyota 4RUNNER SUVs with exhaust tips that can burn people. Repair is free at any franchised Toyota dealer.
Toyota is recalling 425 2010-2015 4RUNNER SUVs because accessory exhaust tips installed before sale can contact people standing behind the vehicle. Contact with the exhaust tip can cause personal injury, and Toyota dealers will complete the recall repair free of charge.
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What's wrong?
The accessory exhaust tip on the 2010-2015 Toyota 4RUNNER is the metal outlet piece fitted at the end of the tail pipe. Its job is simple: finish the exhaust outlet behind the bumper and route hot exhaust away from the back of the SUV. Because it sits at the exhaust outlet, the tip gets hot during normal driving.
On affected 4RUNNER SUVs, the accessory tip was installed by SET or SET dealers and sits where a person standing behind the vehicle can contact it. That creates a burn hazard even though the rest of the exhaust system is working as intended. The replacement tip is smaller in diameter and recessed farther behind the bumper, which moves the hot metal away from casual contact.
There is no warning sign before failure. The practical clue is visual: if an accessory exhaust tip is exposed behind the bumper, treat it as hot after driving and have the Toyota dealer check whether your VIN is included.
Who's affected?
Spans the 2010-2015 model years, all tied to the same exhaust system component.
| 2010 Toyota 4RUNNER | Manifold/header/muffler/tail pipe |
|---|---|
| 2012 Toyota 4RUNNER | Manifold/header/muffler/tail pipe |
| 2011 Toyota 4RUNNER | Manifold/header/muffler/tail pipe |
| 2014 Toyota 4RUNNER | Manifold/header/muffler/tail pipe |
| 2015 Toyota 4RUNNER | Manifold/header/muffler/tail pipe |
| 2013 Toyota 4RUNNER | Manifold/header/muffler/tail pipe |
| Units affected | 425 |
| Field incidents | NHTSA has logged no field incidents to date. |
The year and model narrow the scope, but the VIN decides. Check your VIN to confirm whether your specific SUV is included.
What's the safety risk?
The risk is personal injury from contact with the exhaust tip, especially around the rear bumper after driving. There is no warning sign before contact, so keep hands, legs, and cargo away from the exhaust outlet until the redesigned tip is installed. Repair is free at any franchised Toyota dealer.
What should I do?
- Check your VIN to confirm your 2010-2015 Toyota 4RUNNER is included in this recall.
- Contact a franchised Toyota dealer to schedule the free redesigned exhaust-tip installation that moves the hot tip farther behind the bumper.
- Bring the recall notice if Toyota mailed one. If not, reference recall number 16V577 when you call.
- Keep people away from the rear exhaust tip area until the redesigned tip is installed.
What happens at the repair
At the dealer, a Toyota technician installs a redesigned exhaust tip. The new tip is smaller in diameter and sits farther behind the bumper, reducing the chance that a person standing behind the 4RUNNER contacts the hot exhaust outlet. The replacement parts and labor are free under the recall. The reimbursement plan says Toyota does not expect owner claims, but reimbursement instructions will be provided if claims arise. If you already paid for an exhaust tip repair tied to this recall, ask the service desk for those reimbursement instructions.
| Reimbursement | Reimbursement available |
|---|
Timeline
| August 2, 2016 | Dealer notification began |
|---|---|
| August 3, 2016 | NHTSA published the recall |
| August 7, 2016 | Dealer notification ended |
| September 15, 2016 | Owner notification mailed |
| September 15, 2016 | Interim owner notification (was planned for this date) |
Frequently asked questions
What is recall 16V577?
Recall 16V577 covers 425 2010-2015 Toyota 4RUNNER vehicles with accessory exhaust tips that can contact people standing behind the vehicle and cause burns or personal injury. Toyota dealers will install a smaller, more recessed exhaust tip for free.
What should I do if my 2010-2015 Toyota 4RUNNER is on this recall?
Check your VIN to confirm your specific SUV is included in recall 16V577. If it is, contact a franchised Toyota dealer to schedule the redesigned exhaust tip installation. Reference recall number 16V577 or SET16D when you call. The repair is free.
Is the recall repair free?
Yes. Federal recall law requires the manufacturer to repair the defect at no cost. A franchised Toyota dealer will install the redesigned exhaust tip free of charge, including parts and labor.
What is the safety risk?
The risk is burn injury to someone standing behind the vehicle. The affected accessory exhaust tip can sit where a person contacts it after the exhaust has heated up. The free dealer repair replaces it with a smaller tip recessed behind the bumper.
What if I bought my Toyota 4RUNNER used?
The free repair still applies. Recall coverage follows the VIN, not the first owner. Check your VIN to confirm whether your 2010-2015 Toyota 4RUNNER is included, then call a Toyota dealer with recall number 16V577 or SET16D.
More information
| NHTSA campaign page | nhtsa.gov/vehicle-recalls/16V577000 |
|---|---|
| Toyota customer service | 1-866-405-4226 |
| NHTSA recall # | 16V577 |
| NHTSA recall # (full) | 16V577000 |
Source documents
-
Download Recall Document (PDF) (PDF) - Download Recall Investigation Document (PDF) (PDF)
- Download Owner Notification Letter (PDF)
- Download Owner Notice (PDF)
- Download Recall Report (PDF)
- Download Quarterly Report (PDF)
- Download Recall Acknowledgement (PDF)
This article is generated from NHTSA's primary recall filings and reviewed against the source on May 31, 2026. RecallNotify does not paraphrase NHTSA's consequence language; that text is reproduced as written above. Editorial standards →