Thousands of Toyota owners are about to get some unsettling mail. The carmaker has issued a recall for more than 54,000 2025 Toyota Sienna Hybrid minivans due to a potential safety hazard in the second-row seats. According to documents filed with the National Highway Traffic Safety Administration (NHTSA), a manufacturing glitch caused by an incorrect welding machine setting may have led to seat rails that aren’t properly welded—raising serious concerns about passenger safety during a crash.
The Problem: Faulty Welds in Second-Row Seats
The issue traces back to a welding machine setting error at one of Toyota’s assembly plants. The defect affects the seat rails in the second row, which might not have received full weld penetration during production. The result? A potential loss of structural integrity that could prevent the seat from properly restraining passengers in the event of a collision.
In the NHTSA recall notice, Toyota warned:
“Due to a changed setting of a welding machine during assembly, there is a possibility that certain seat rails contain welds that are not fully penetrated.”
In layman’s terms—if the welds don’t hold, the seat may shift or detach under impact, increasing the risk of injury. That’s a terrifying thought, especially considering the Sienna Hybrid is a go-to family minivan, often carrying children in those very seats.
Which Vehicles Are Affected?
The recall exclusively targets the 2025 Toyota Sienna Hybrid, which rolled off the production line earlier this year. All affected vehicles share the same issue related to seat-rail welding. Toyota’s internal recall identifiers for this issue are 25TB12 and 25TA12.
Here’s a quick overview:
| Model Year | Vehicle | Units Recalled | Defect | Recall ID (Toyota) |
|---|---|---|---|---|
| 2025 | Toyota Sienna Hybrid | 54,631 | Improperly welded second-row seat rails | 25TB12 / 25TA12 |
If your Sienna was manufactured in mid-to-late 2024, it’s very likely included. The official recall filing was submitted on October 7, 2025, and letters notifying owners will begin going out on November 21, 2025.
What Toyota Owners Should Do Next
If you own a 2025 Sienna Hybrid, don’t wait for the letter—check immediately. Toyota is advising all affected owners to bring their vehicles to a dealership, where the second-row seat rails will be inspected and replaced free of charge. Labor and parts are fully covered.
To verify whether your vehicle is affected:
- Visit the NHTSA recall lookup tool.
- Enter your 17-digit Vehicle Identification Number (VIN) or license plate number.
- You can also search by make and model if your VIN isn’t handy.
Alternatively, you can call Toyota’s customer service line at 1-800-331-4331 for assistance.
If you recently purchased or leased a 2025 Sienna Hybrid, dealerships should already be aware of the recall. It’s worth asking during your next service visit—even if you haven’t received the notification yet.
What Happens If the Seats Aren’t Fixed?
An improperly welded seat rail isn’t just a minor flaw—it’s a structural safety risk. In a moderate to high-speed crash, the weld could fail, compromising the restraint system and the seat’s ability to stay anchored. That could cause serious or even life-threatening injuries to anyone sitting in that seat.
The recall notice specifically warns of “loss of structural integrity” and a heightened risk of injury during a collision. Thankfully, Toyota says there have been no reported injuries or accidents linked to this defect so far.
Why Recalls Like This Matter
Seat-structure recalls, though not as headline-grabbing as brake or airbag issues, are among the most critical because they directly affect passenger protection. NHTSA data shows that over 31 million vehicles were recalled in 2024 alone for various defects. And while most owners respond quickly, many cars still go unrepaired—sometimes because drivers simply don’t realize their vehicle is included.
Here’s the bigger picture:
| Year | Total U.S. Vehicle Recalls (All Manufacturers) | Vehicles Affected (Millions) | Top Recall Type |
|---|---|---|---|
| 2023 | 953 | 31.3 | Airbag & seatbelt defects |
| 2024 | 1,021 | 33.7 | Electrical & structural issues |
| 2025* | 460 (YTD) | 17.8 | Manufacturing defects (seat, weld, software) |
(*Data through Q3 2025, per NHTSA reports)
Recalls are typically voluntary but supervised by federal regulators. Automakers are required by law to notify owners and provide a free fix. In Toyota’s case, the company has already alerted dealerships and begun preparing replacement parts.
FAQs:
Which Toyota vehicles are part of this recall?
Only the 2025 Toyota Sienna Hybrid models are affected by the seat-rail welding defect.
How serious is the issue?
The defect could cause the second-row seat to fail during a crash, potentially leading to serious injury.
How do I check if my Sienna is included in the recall?
Use the NHTSA recall lookup tool and enter your VIN or license plate number to confirm.
