Toyota revisits HiLux Rogue roller-cover fault

TOYOTA Australia is calling almost 17,000 HiLux Rogue owners back to dealerships to address a powered roller-cover fault for the second time in little more than two years, after its earlier countermeasure failed to fully resolve the issue.

The latest Customer Service Exercise (CSE) affects approximately 16,995 HiLux Rogue dual-cab utes produced between May 29, 2020 and April 8, 2024, all fitted as standard with the power-operated tub roller cover.

Toyota says the roller cover may become jammed or unable to open or close. If this occurs, its electric motor may remain active and potentially overheat, with owners in some instances able to detect a burning smell or smoke.

Affected vehicles remain safe to drive, although Toyota advises owners experiencing signs of overheating to stop operating the roller cover and contact a dealership.

The latest campaign represents a further countermeasure for a problem Toyota attempted to rectify in July 2024, when 14,032 HiLux Rogues produced between May 2020 and November 2023 were subject to a near-identical CSE.

That earlier campaign also addressed a roller cover that could jam or become inoperative, allowing its motor to continue running and potentially overheat.

At the time, dealers inspected the motor for signs of previous overheating, replaced it where necessary, checked and adjusted the roller-cover track width, and updated the system’s electronic control unit software. The work was expected to take around 2.5 hours.

Under the latest campaign, dealers will repeat those measures but also install metal drive-pin connectors where required.

Toyota says revised ECU software changes the roller cover’s limit-switch logic in a bid to further reduce the possibility of motor overheating. It also enables the cover to be opened and closed using the vehicle’s key fob or the lock/unlock switches on the driver’s door.

The updated inspection and repair procedure is expected to take up to 3.5 hours, although Toyota says vehicles may need to remain with dealerships for longer depending on workshop scheduling.

Importantly, Toyota says some owners who had the previous CSE completed may be contacted again for the latest rectification.

The Rogue’s roller cover has an even longer history of remedial work.

In 2021, Toyota conducted a separate CSE covering 281 HiLux Rogues after identifying ECU software behaviour that could cause abnormal roller-cover operation and motor overheating. A related safety recall covering 683 vehicles concerned a different roller-cover wiring-harness issue and potential fire risk.

Toyota will contact affected owners directly, with repairs carried out free of charge.

Owners may also contact their preferred Toyota dealer or the Toyota Campaign Helpline on 1800 987 366, quoting the vehicle’s 17-digit VIN.