Thursday, June 2, 2005

2005 Toyota Prius

Software glitch spurs Prius probe

Government will investigate 75,000 Toyotas after reports of stalled engines.

By Jeff Plungis / Detroit News Washington Bureau

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WASHINGTON -- The National Highway Traffic Safety Administration said Wednesday it is investigating reports that a software glitch can stall Toyota's popular Prius hybrid at highway speeds.

In its initial report, NHTSA said it has received 33 reports of stalled engines in 2004 and 2005 model-year Prius cars. More than 85 percent of the complaints involved vehicles stalling at highway speeds, or 35 mph to 65 mph. The investigation covers approximately 75,000 cars.

NHTSA is trying to learn more about two "special service campaigns" Toyota conducted in January and May 2004 to correct software on the computer that controls the Prius's hybrid system.

In October 2004, Toyota issued a technical service bulletin to dealers spelling out how to correct computer problems on Priuses made in the 2004 model year and the first part of the 2005 model year.

While the investigation is in its preliminary stages, the probe raises new questions about the long-term reliability of gasoline-electric hybrid technology that automakers are embracing as a way to improve fuel economy. Because the incidents could be related to a software glitch, NHTSA wants to determine if Prius owners are experiencing a new kind of computer "crash."

"All complainants reported that the engine shut down suddenly without warning and at least 50 percent of the complainants (reported) that when the engine shut off, the vehicle would not restart and had to be towed," NHTSA's defect investigation summary stated.

Though they are rapidly gaining in popularity, the gas-electric cars are still a tiny fraction of all the vehicles on U.S. highways. In that sense they are an unproven technology. Besides the alleged software defect, there are questions about the added costs of the electric powertrains and the longevity of their enormous battery packs.

Toyota Motor Corp. says it is too early to reach any conclusions about the complaints, and said it will work with the National Highway Traffic Safety Administration and customers to investigate.

Toyota spokesman John McCandless disputed the notion that hybrid powertrains are unproven technology. Since a redesign in the 2004 model year, 97,677 Priuses have been sold, McCandless said. Going back to 1997, when the first Prius was sold in Japan, 335,780 have been sold worldwide. The first Prius was sold in the U.S. in 2000.

"Most owners have not had any sort of problem," McCandless said. "It's too early to determine a specific problem right now. We need some time to investigate."

Hybrids have become an integral part of Toyota's product plans. Its second and third hybrid models, the Lexus 400h and Highlander SUVs, have just gone on sale. The company also plans hybrid versions of the Lexus GS and Camry sedans. Company executives say at some point in the future, they may offer a hybrid option on every model they sell.

Besides the complaints to Toyota and NHTSA, Prius owners are sounding off on Internet message boards.

In a March 8 positing to Edmunds.com's "Town Hall," one Prius owner, identified as "stevedebi," described how all of the warning lights on his dashboard suddenly lit up and the gasoline engine suddenly shut off. He made it home on battery power but had to coast into the driveway.

The car was towed to a dealer the next day. The dealer reinstalled the car's computer software, leaving the owner to wonder if the glitch could bring his hybrid to a stop again in the future.

Industry observers will be watching in the coming weeks to see if more Prius owners emerge with similar stories. If the complaints don't grow much beyond what NHTSA and Toyota have already announced, the impact will be minimal, said Jess Toprak, director of pricing and market analysis for Edmunds.com.

"Overall, there will not be a dramatic impact on the demand for this car," Toprak said. "The demand is so high."

Hybrid enthusiasts say they have heard very little about the stalling problem. Brad Berman, editor of hybridcars.com, said he has not seen any complaints on his web site or on Prius discussion forums.

You can reach Jeff Plungis at (202) 906-8204 or jplungis@detnews.com.