Product recall: Car giant Toyota expands recall to nearly 50,000 vehicles over seat safety defect

Toyota has been forced to expand a recall after learning thousands of additional cars also contained the safety concern.

The Japanese car manufacturer issued an expansion to their March recall of Kluger cars earlier this week, due to a supplier fault impacting the return spring on the vehicle’s second row seats.

“A combination of recliner return spring orientation and outer clearance between the recliner guide and ratchet may cause the recliner teeth to not fully engage during seat back adjustment,” Toyota said in a recall notice.

“This may lead to the seat back not remaining in a locked position and failing to properly restrain occupants, which increases the risk of injury.”

The recall initially affected 34,000 Klugers manufactured between March 31, 2021, and November 10, 2023.

It’s now been expanded to include all Klugers made between November 11, 2023, and June 10, 2025 — an estimated 15,000 extra cars across Australia.

Replacement springs are being offered by Toyota, with the owners of involved vehicles urged to contact their dealership.

“For all involved vehicles, Toyota dealers will replace the seat back return springs in the recliner assembly, free of charge to owners,” they said.

The major recall comes amid a highly successful year for Toyota, who were crowned Australia’s most popular car brand back in April.