Toyota RAV4 production paused after deadly factory explosion, Australian impact unclear

An explosion at a Toyota supplier’s factory in Japan has left one worker dead and injured two others, with the flow-on effects suspending production of the popular RAV4 SUV.

Automotive News reports an explosion occurred at the Chuo Spring Co. facility in Toyota City on March 6. Toyota is the spring manufacturer’s largest shareholder.

While the cause of the explosion is yet to be determined, this has subsequently resulted in production pauses for the Toyota RAV4, which is built in Japan for multiple markets including Australia.

“We are seeking further information from our production team in Japan,” a spokesperson for Toyota Australia told CarExpert.

“At this stage it’s too soon to know if this will impact RAV4 production for Australia.”

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According to Automotive News, Toyota suspended operations at one of two lines at the Takaoka assembly plant and two lines at the Nagakusa factory – both of which produce the RAV4 – on March 10.

All Australian-delivered RAV4s are produced in Japan, with delays in output threatening to unravel Toyota’s projections for its SUV to become the best-selling car locally this year.

In 2024, the Toyota RAV4 came a close second to the Ford Ranger in the sales charts, with strong supply of the SUV in the latter half of the year having been projected to continue into 2025.

While a new-generation model is expected to be unveiled this year and go on sale in 2026, Toyota Australia vice-president of sales, marketing and franchise operations Sean Hanley said in January the RAV4 could take the sales crown in 2025 and beyond.

“Utes could potentially hold out for another year, but beyond that I don’t think so,” said Mr Hanley.

“Last year was the first time an SUV was Toyota’s best-selling vehicle. For the previous nine years it was HiLux.

“We already know the number of ute models available to Australian buyers will expand rapidly, and they will all be competing for an overall ute market that will remain steady… as a result, it may be that an SUV could rise to the top of the national sales charts in the next year or two.

“Just maybe, that SUV will be a Toyota RAV4 Hybrid.”

Though last year’s run up the sales charts was believed to be linked to the clearing of huge order backlogs from previous years – which stretched to beyond 24 months for some variants – Toyota has claimed its order books remain strong.

In the first two months of 2025, Toyota has delivered 9481 RAV4s, a significant 87.6 per cent increase on the same period last year, and well ahead of the 8294 Rangers delivered so far.

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