- Recall covers all 2025 Sienna Hybrids built between January and July 2025.
- Faulty welds on second-row seat rails may compromise crash protection.
- Dealers will replace affected seat rails free of charge starting this December.
If there’s one factor that consistently tops the list for minivan shoppers, it’s likely safety. These vehicles carry families, friends, and everything in between, often with the most important passengers seated in the second or third row.
That second row is potentially risky in over 50,000 Sienna Hybrid minivans from the 2025 model year, according to Toyota. A welding machine set to the wrong setting might be to blame for them not holding up in the event of a crash.
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Documents filed with the NHTSA trace the issue to supplier Toyota Boshoku Kentucky in Harrodsburg, KY, where a welding machine was incorrectly calibrated during production.
The error occurred as some second-row seat rails were being assembled, meaning weld penetration might be incomplete. As a result, the affected seats could fail to meet safety requirements in a collision.
Discovered in Testing
Toyota says the problem surfaced during internal testing this summer, when a prototype seat failed to meet company standards. Further investigation confirmed the concern. Some seat rails could lose strength in a crash setting.
While the situation doesn’t necessarily violate federal safety standards, Toyota is voluntarily initiating a recall in the name of safety. It’s worth noting that the brand says it’s unaware of any warranty claims or field reports linked to the situation.
The issue also only applies to Sienna Hybrids built from January 14 through July 24 of 2025. It doesn’t affect any other two or three-row models from Toyota or Lexus.
Owners can expect official notification between November 21 and December 6 of this year. Dealerships will replace the seat rails in all 54,631 affected vehicles at no cost to owners.
Toyota says dealers are being informed immediately, with recall operations filed under campaign codes 25TB12 and 25TA12. Those who want to check to see if their car is involved can search for it by entering their VIN at NHTSA.gov or by contacting their local dealership.
