Letter about DPF from Toyota Australia

[JohnLynn Senior Member Find all posts View Profile Close JohnLynn]

It has been a very long time since I posted on here but I would like to ask who has received a letter which I will copy/paste a couple of relevant bits from:


This letter provides you with information concerning the availability of a DPF repair that is FREE OF CHARGE and an extension to Toyota Australia's warranty for your vehicle untiI that repair is completed.

The DPF repair involves fitting of a replacement system that incorporates changes made to address the defect.

lf you wish your vehicle to receive the DPF repair, or are unsure whether the DPF repair has been completed for your vehicle, Toyota Australia invites you to contact your closest/preferred Toyota Deater to have them assess the DPF system in your vehicle, and, if required, they will organize the DPF repair to be carried out on your vehicle as soon as practicable, and at no cost to you.

I visited a dealer in Rockingham WA and they told me it could take 3 months to get the part. When I asked what the part was expecting a new DPF or at the very least a modified 5th injector the answer was "a spacer"
Anyone have any information about this recall please?

[bing10 Junior Member Find all posts View Profile Close bing10]

I havent been to a toyota dealer for 5 years. Dec 2024, I went for a service and was told my DPF is set for a free replacement. Booked in for 3 weeks later and was replaced . They said they needed the car all day but called at 1pm to say all done. At pick up I did ask, why I didnt get a letter to advise of recall, , but got no answer. I also asked how much this job would cost if I had to pay, but they wouldn't answer.

Anyhow, my 2016 VX with 130,000km got its problem free DPF replaced for free. A very pleasant surprise.

[Not Enough Time Junior Member Find all posts View Profile Close Not Enough Time]

I have a Aug 21 GLX supposedly after the DPF fix. In October at 125 000km it developed a problem where it was taking up to 3 hours to complete a Regen or burn, using an extra 2 to 3Lof fuel per hour.
Under warranty Toyota replaced 4 injectors, saying there was a Toyota service bulletin recognising the fault. Few thousand km later it was taking up to 4 hours to complete a burn.
Into the dealer again, they found the DPF injector housing was partially blocked and DPF injector Carboned up.
Over the last 2000km, the regens happen after ca 380km of Highway running and are completed in 10-12 minutes as opposed to original 300km and 25 minutes (as per vehicle manual).
Ultimately I'm happy as I effectively got new injectors 125000km early.

[JohnLynn Senior Member Find all posts View Profile Close JohnLynn]

I contacted another dealer who said they would test my DPF and if they did not find a problem they would not do anything but wait until it failed. I have since sent an email to Toyota Australia asking for clarification but apparently it takes them 48 hours to respond. Not impressed so far!

[watsea Member Find all posts View Profile Close watsea]

I received a letter several weeks ago. My 2019 GXL has done 112k km without any DPF problems. I had thought that most of the defective ones had occurred prior to the time when I purchased mine. Most of the vehicle’s driving is at least an hour or more on freeways or highways.
Though I have not been troubled with the DPF, I rang my dealer as the vehicle is due for a service in February and before a trip. Discussion with the Service rep was that they will replace at no cost to me even though no problems with mine so far. I was happy as I would not like any problems to occur on a lengthy trip where a replacement item may take time to arrive and replace, causing unwanted delays. I suspect the dealer receives funds from Toyota for service work so it benefits the dealer’s business as well. I was told that it can take three to four weeks for the parts to be delivered.

A DPF replacement is scheduled for the same day as a service in mid February.

[404pug Avid PP Poster! Find all posts View Profile Close 404pug]

The dpf on my 2016 was replaced at my request at about 60000+km. This was 2 or 3 years ago when the issue was all over the news. I said I had seen a bit of white smoke and that my scanguage was showing funny, irregular readings and I was off onto remote WA deserts. No questions asked. " we can do it next Tuesday". The whole housing and 5th injector were replaced. Warranty on dpf extended to 10 years from date of 1st rego. No further issues in subsequent 30000+ km. The burn patterns and times and km apart are different but all works fine. At the time they were replacing them for anyone who asked. Took about 3 hours.
By the way does anyone have any updates on the class action re. dpf?
PS Years ago mine had the dpf light installed (works fine) and the manual switch (has never worked despite 4 or 5 attempts by the dealer.

[JohnLynn Senior Member Find all posts View Profile Close JohnLynn]

The dpf on my 2016 was replaced at my request at about 60000+km. This was 2 or 3 years ago when the issue was all over the news. I said I had seen a bit of white smoke and that my scanguage was showing funny, irregular readings and I was off onto remote WA deserts. No questions asked. " we can do it next Tuesday". The whole housing and 5th injector were replaced. Warranty on dpf extended to 10 years from date of 1st rego. No further issues in subsequent 30000+ km. The burn patterns and times and km apart are different but all works fine. At the time they were replacing them for anyone who asked. Took about 3 hours.
By the way does anyone have any updates on the class action re. dpf?
PS Years ago mine had the dpf light installed (works fine) and the manual switch (has never worked despite 4 or 5 attempts by the dealer.

That is interesting so thanks for posting. I too have been curious about the class action, the last I heard was that Toyota were appealing the amount offered but there has been a deathly silence ever since. So being a cynic I presumed that this latest letter was an effort by Toyota to not pay out anything at all.
As you can probably tell from my comments so far I am not happy about the whole issue, although I perhaps should have been more proactive like you were to get a result.

[404pug Avid PP Poster! Find all posts View Profile Close 404pug]

Go to another dealer and say you have seen white smoke. say that over east replacements are happening. Why not yours? good luck. Tell them that you are going remote and Toyota will have to wear the tow out when it malfunctions in the middle of nowhere because they didn't replace a known faulty part.

[RPP Senior Member Find all posts View Profile Close RPP]

I have a 2018 GXL.
Circa 2019 my Dealer replaced the DPF assembly, under a directive from Toyota, and I got a 10year unconditional warranty.
Never had any problems with the old or new DPF.
Also had the Manual PDF button installed and Custom Mode (2) correctly enabled . Used it in the bush a few times and it works fine.

I've recorded stats for all DPF regens from new - will clock 200,000Kms shortly. I'll publish the charts when I get there.
I've also concluded that it takes 6-10Kms, in winter, for the engine to reach temperature for a DPF regen to occur/resume. If you do regular shorter trips the DPF regen mite not function properly,

My guess is that the class action had the wind taken out of it when Toyota replaced the original DPFs for free and added a 10year unconditional warranty.

[geo Junior Member Find all posts View Profile Close geo]

RPP did you get the manual burn switch installed as part of the new dpf assembly?
I had my dpf renewed a while back with the 10 yr warranty etc but they refused my request to install the switch.
Should I now go back to Toyota & ask {demand} a manual burn switch be installed?

[404pug Avid PP Poster! Find all posts View Profile Close 404pug]

What they approve appears to change over time. I requested the light and switch when 1 of the many dpf updates was being done. Light is excellent and comes on when scanguage shows dpf shows 100% and goes off at about 4-6%. The switch is a lost cause after about 4 or 5 attempts.

[RPP Senior Member Find all posts View Profile Close RPP]

RPP did you get the manual burn switch installed as part of the new dpf assembly?
I had my dpf renewed a while back with the 10 yr warranty etc but they refused my request to install the switch.
Should I now go back to Toyota & ask {demand} a manual burn switch be installed?

I asked for the DPF manual regen switch to be installed around mid 2018 sometime. This was because I drive long distances over grassy terrain, tinder dry spinifex and 2m cane grass (eg the Canning Stock Route, Oombulgurri Track etc).
My Dealer sent the request to Toyota and got the thumbs up. I was told that farmers, forestry workers, and drivers like me would get approval from Toyota. They also installed it for free!.
My Dealer enabled Custom Mode 1 but failed on 4 attempts to enable Custom Mode 2. I eventually found a different Dealer who had successfully enabled Custom Mode 2 for a few Prados before me.

If you aren't going to be driving over tracks of tinder dry grass then you can live without Custom Mode 2. Scanguage III will tell u all you need to know.
But it was a little scary driving the CSR during a DPF regen seeing the DPF and exhaust temps rocket past 600C. There is are a few burnout wrecks on that track.

[geo Junior Member Find all posts View Profile Close geo]

I asked for the DPF manual regen switch to be installed around mid 2018 sometime. This was because I drive long distances over grassy terrain, tinder dry spinifex and 2m cane grass (eg the Canning Stock Route, Oombulgurri Track etc).
My Dealer sent the request to Toyota and got the thumbs up. I was told that farmers, forestry workers, and drivers like me would get approval from Toyota. They also installed it for free!.
My Dealer enabled Custom Mode 1 but failed on 4 attempts to enable Custom Mode 2. I eventually found a different Dealer who had successfully enabled Custom Mode 2 for a few Prados before me.

If you aren't going to be driving over tracks of tinder dry grass then you can live without Custom Mode 2. Scanguage III will tell u all you need to know, but it is a little scary driving the CSR during a DPF regen seeing the DPF and exhaust temps rocket past 600C.

Thanks for the reply RPP
What are these Custom Modes 1 & 2?
I've only got a Scangauge2 so I assume that won't tell me anything. No idea what program was loaded when my DPF was upgraded.

[RPP Senior Member Find all posts View Profile Close RPP]

When I had the DPF Manual Regen button installed I had two "Custom Mode" options available that a Dealer could enable for me.
The first option would display the status of DPF regens when under way - how this works is different for older vehicles I vaguely recall .
The second option, when enabled, would allow me to press the button to initiate a regen manually under specific conditions.

The manual regen button is normally disabled unless the ECU alerts you to pull over and press it. The conditions might occur when the DPF is full and various criteria are met.
When Custom Mode (2) is enabled by the Dealer I can press the button when the DPF 's saturation level reaches a minimum of 28% (and engine operating conditions are met).

[404pug Avid PP Poster! Find all posts View Profile Close 404pug]

Hmm. At about the 4th attempt to get the switch to work the dealer said it would only work when dpf was overfull. 180% rings a bell. That said on a trip doing all of the Beadell roads in WA in 2023 everyone on the trip managed the hot exhaust long dry grass scenarios by stopping over bare patches only and thorough underbody checks every hour or so. Plenty of pre dpf cars have burnt in long grass.