2022/2023 Tonneau cover recall

Mine was $1250, added as an accessory.

 

Just stay on them. I had to call back a few times over the course of 2 weeks before something really got done..paid off though since I ended up with my refund.

 

I opened up my case with the brand engagement center this am, we will see how it goes and post back.

My dealership is clueless and/or unwilling to do anything.

 

Just talked to the Toyota manager they have me booked in tomorrow to remove the tonneau cover and they're giving me msrp plus 1 hour labour refund. Over $2000 cdn. My buddy has same tonneau cover on his tundra and his got removed today and same thing he got refunded. Comox Valley Toyota!

 

So, I just drove 1600 miles with the Tonneau cover from the bottom of Florida, to the top of New England, almost to the Canadian border, with no issues(75 -> 95 -> 87 ). Now, I had the back full of gear I was transporting, so I was a bit concerned before I left, but had no issues. Now, one thing I got to thinking about on the trip, the way this cover holds itself down, are the 2 thumb screws, at the front, and then at every joint, there is a set of retracting latches that snap under the side rails. One thing I always do, is I tie 2 ratchet straps diagonally from corner to corner, and 2 across at about 1/3 and 2/3 points with my siderail brackets. I'm wondering, if the box being made of composite material, is flexing enough(more then the metal boxes maybe?) to pop these latches out from under the rails. Anyhow, not one issue on the entire trip, my typical speed when all was good with traffic and such, was 85 mph, with bursts to low 90's, but more often then not, 80-85 with the flow of normal traffic around me. So, there was plenty of wind and bouncing (have you been on South Carolina 95 or Delaware 295 or 495 or whatever it was there - Actually hit a bump at about 50 or so coming off a bridge into Delaware, that I think we almost went airborne. It set off my Security Camera as some sort of accident or impact! I was like, what to h*l was that beep about? and then saw the Action light on the camera lit)

 

I contacted Toyota Brand Engagement and discussed that my OEM cover is a necessity due to my line of work. They encouraged me to go to the selling dealer and plead my case with the parts manager... so off to the dealership I went.

My dealership parts manager and I have very good relationship as I do have (4) toyotas. Well, after pleading my case it was taken into the corporate meeting and eventually the decision to call the DSP. Today I got a call from the dealership and they have set up an appointment for me in the morning to remove the cover and Toyota is issuing me a refund of $1350.

So my advice to anyone who doesn't want to wait for the Recall Fix, I would encourage you to calmly plead your case with your selling dealer, and you could wind up getting a refund too.

 

I am waiting. I hit the bolts with Loktite. I have a short box so I do not have that extra panel with no latches. When they decide to replace it I will. The dealership manager still has his on ......food for thought

 

Comox....like BC Comox??

 

This is my plan too. I’ve done a couple long road trips and haven’t had any issues. I’m a pretty risk adverse person but I feel confident the issues where it might come off are when driving with it in the open position. Which I have rarely done. But definitely understand others who make a different choice.

All around though this is being handled extremely poorly by Toyota which is disappointing.

 

Every time I have the cover open I reach under and test the knobs. So far every time they are still tight. This includes multiple long (10+ hour) road trips. I did put blue loctite on them when I installed it. But I am very confident they will not come loose all of a sudden. So I am not at all worried here.

 

You should be good with the loctite, they aren’t going to come off with that

 

Just seeing this, was about to buy the Bakflip MK4. Guess I will give the rough country one another look or wait and see how this plays out.

 

I would like to bring to the attention of those using loctite to secure the bolts holding the cover…

The failure has nothing to do with lose or missing bolts. The failure is related to the latches and running the truck with the tailgate open. I have it on good authority this is what the recall is focused upon.

I understand from my sources that Toyota will be completely replacing the covers, there will not be a repair to the existing cover. If the issue were just a bolt failure that would have been easy to address and fix.

I opted to go the route of refund for (2) reasons. First I need the cover to secure my tools and equipment daily so having my dealer remove the cover for several months is not an option. Second, I was experiencing quality issues with my cover and needed the dealer to address those issues while under warranty as the 12 mo 12000 mile for accessories is just a couple thousand miles from expiration.

My selling dealer removed my cover today and issued me a full refund so I can buy another cover of my choosing right away.

 

if that’s the case , Bak totally shit the bed on the design

I’m glad I went with undercover again

 

If this is correct, that goes back to what I was thinking re: the box flex - with the tailgate open, the sides are even more apt to flex and allow the latches on the sides to come out from under the rails. So, my straps method is probably good insurance against that. Not sure how they can redesign the cover to fix that (longer latches maybe?)

 

So building on your theory which I think is super interesting the flexing could also be slowly compressing the latches while driving. There would be constant negative pressure on the cover at highway speeds and the compressed latches would eventually give way under the pressure and up lifts the cover and upsets the air flow and…… up up and away ripped from the loctited (just a pun) bolts.

I think that is an interesting scenario… and sounds quite plausible in the words of “The Myth Busters”.

 

The bed isn’t flexing that much, that’s stretching, it’s just a shitty design and needs improvements

no other cover is having problems only bak

 

You could be right, I'm just trying to think of reasons the cover would come off while driving. This was just one possibility I wondered about.

I wish Toyota would just come out and explain what it is, that is causing the issue. Even if they haven't a fix for it yet.

 

they may be waiting for bak

 

I am a Professional Mechanical Engineer with 37 years experience. I am sure the Toyota Engineers are going through a root cause analysis on this failure. Until they know for sure what the root cause is and test it for themselves they will not disclose anything. Right now they are just protecting truck owners as well as the general public to limit or eliminate their liabilities by issuing the recall as they or their dealerships sold and installed the covers.

Personally I think those who were able to get their money back from their dealers in order to find another alternative is the right move. It sucks what has happened but no auto manufacturer issues recalls without serious consideration.

As far as BAK is concerned we think its the exact same cover but do we know for sure? If it really is the same they would most likely cover liabilities associated with defects due to design, materials and workmanship but possiblly not on the installation especially if you installed it yourself.

 

Fair assessment. Thanks.

In the case of BAK owners who installed themselves (I am one, and seems most/all BAK owners installed themselves best I can tell), if BAK would be responsible for design flaws but not installation flaws, then for people who put Loctite on the front nuts, or like me who replaced the thumb nuts with nylon insert steel nuts, would BAK then be free from liability because we did not exactly follow their installation instructions?

 

It's possible even if you think its a good solution. From my experience once an owner takes on the responsibility to install then he also takes on the responsibility to follow the instructions to a tee and make sure the product is fit for the appliction. I am not sure what the warranty card for the BAK covers say or even if they have one.

I am also aware some suppliers provide piss poor instructions but in those cases you always need to go back to the manufacturer for clarity if need be.

 

Ketterus posts this isnt the problem but if the 2 retaining nuts fall off......I gotta think it is a possibility. In reality what is holding it on if the 2 thumbwheel nuts are rolling around in the box? The only nuts involved. Just going with common sense ??? NyLocks or Loktite.....I keep rolling along

Mine hasnt budged. Up or down, 40 MPH to 85 MPH.

 

I got my recall letter and it just has a QR code to scan to let Toyota know if you have one or not, still waiting for a new one I guess.

 

That was not how my letter was set up. Maybe how Canada is doing it different.

 

I just got a reply from NHTSA to a letter I wrote them a couple months ago. It was a pretty comprehensive letter that discussed recall processes in general but didn't really provide any information that would help with getting a faster resolution. Bottom line was to "keep working with Toyota and your dealer" for resolution or refund. But there was one small bit of new information where NHTSA discussed this particular recall where it said that the cover "joints may come loose". I would interpret that as the hinges between panels and that the pins or other fasteners may come loose and one or more panels could go flying away. Anyway, just a little more data. I am going to call Toyota again tomorrow. Probably a waste of time but who knows?

 

My Canada letter was the same. I did the QR code, clicked equipped , it sent me a thank you for removing it......I laughed. Its still on LOL

 

The recall notice has disappeared from my Toyota app. It now says there are no safety recalls. Did something change?

 

I just looked and mines still there ( the recall and the cover )

 

It comes and goes from the app. If you refresh the screen it usually comes back.