Good Old Kentucky Reliability?
My 2019 ESh which was built in KY is nowhere near as well built as the Japanese-made model I had before it. It doesn't rattle so much as squeak - a lot - and it doesn't matter what the weather is. I've had condensation inside the car on the windows and entertainment/nav screen. I also have wind noise on the highway around the driver's door (I have the double-pane glass). Several months ago I got in the car and a plastic **** fell out from underneath the dashboard onto my foot.
For a bigger sample, you can look to the J.D. Power Plant Assembly Line Quality Awards (keeping in mind that any such survey that agrees with one's own opinions is a great survey, and a survey that disproves one's own opinion is full of baloney and "to be taken with a grain of salt"). The top rated assembly plant in the Asia Pacific region is the Toyota plant in Japan. The top rated assembly plant in Europe and Africa regions is the Toyota plant in Turkey. The top rated assembly plant in North/South America is...not the Toyota plant. The highest rated Toyota plant, in 4th place, is the plant in Canada. In other words, the plant not mentioned anywhere here is the Kentucky plant. There's a reason for that.
If this was a Toyota I wouldn't care as much. Would I buy it again? Probably. Nothing major, but the car's only 1 year old anyway and I don't drive it much anymore due to pandemic. But a Lexus shouldn't squeak and rattle and have pieces falling off in only a year.
For a bigger sample, you can look to the J.D. Power Plant Assembly Line Quality Awards (keeping in mind that any such survey that agrees with one's own opinions is a great survey, and a survey that disproves one's own opinion is full of baloney and "to be taken with a grain of salt"). The top rated assembly plant in the Asia Pacific region is the Toyota plant in Japan. The top rated assembly plant in Europe and Africa regions is the Toyota plant in Turkey. The top rated assembly plant in North/South America is...not the Toyota plant. The highest rated Toyota plant, in 4th place, is the plant in Canada. In other words, the plant not mentioned anywhere here is the Kentucky plant. There's a reason for that.
If this was a Toyota I wouldn't care as much. Would I buy it again? Probably. Nothing major, but the car's only 1 year old anyway and I don't drive it much anymore due to pandemic. But a Lexus shouldn't squeak and rattle and have pieces falling off in only a year.
BTW...In the late 80's, in America, one could get a Japanese built Accord or an identical American made Accord, but it was based solely on which state one lived in. While they were both good, reliable cars, they had some idiosyncrasys as noted by M&M in the car chat forum.
In my observation, when the 2016 ES built in Kentucky came out, there were many noticeable differences from the Japanese models from cheaper interior materials, to the way the trunk latch closed. The horizontal wood applique above the glove compartment door was never properly aligned in the KY ones, and the gap was never straight. The front seats feel felt different than the Japanese built models. The Japanese built models blew colder A/C, than the US built models. Whoever wants to disagree with me, that is fine. But these are my observations. I felt the quality of the US built ES became the same quality as the Avalon. I own one of the last Japanese built ES's (build date was 11/2016), and I am extremely happy with it as far as the fit and finish, and structural integrity of the vehicle (I have no squeaks or rattles at 38K miles now). My vehicle represents what Lexus was and what is should be now. Back in the summer of 2017, I requested a Japanese built model, and I got it. If I had to get another new ES, I would get a Japanese built one. If a Japanese built one was not available, I would leave Lexus. I am not bashing the American auto worker, as my friend has a 2013 Honda Accord built in Ohio, and the quality is excellent. Sitting the latest Gen US built feels as the same quality as an Avalon, in my opinion.
I'm a long-time Consumer Reports member, and I noticed the ES has slipped from having the coveted "Excellent" CR reliability rating to the lesser "Above Average" rating. My 97 Kentucky-built Avalon was mediocre at best, but my 01 Tundra was better. Hopefully, Lexus has learned from the mistakes of the past and will continue to improve its U.S. build quality.
I had a 2013 Accord from Ohio and now that you mention it, that car was built better than the ESh I have now. I hated the Accord for other reasons (too noisy, horrible suspension, etc.) and so I got rid of it quickly. And I had more problems with that Accord than any other Honda I had ever had, but they weren't related to assembly (multiple software recalls, bad struts, and so on). But it did not squeak or rattle, there were no leaks, none of that. I understand the new Accord has hood flutter and things like that.
There's a ridiculous video taken at the Kentucky plant showing how many JD Power awards the plant has won over the years, and it shows the workers "making" a car. If we were to believe the video, with the glove-covered hands feeling for gaps, putting logos on and 4 people checking the trunk, it would take 4 days just to make one car. I guess mine was built on a Friday afternoon, otherwise the gap between the driver's door and the dash would be the same as the gap between the passenger's door and the dash. And my rear window wouldn't get damp inside. And the console wouldn't squeak. And I wouldn't wonder what exactly that black plastic cap is that fell out of my dashboard.
There's a ridiculous video taken at the Kentucky plant showing how many JD Power awards the plant has won over the years, and it shows the workers "making" a car. If we were to believe the video, with the glove-covered hands feeling for gaps, putting logos on and 4 people checking the trunk, it would take 4 days just to make one car. I guess mine was built on a Friday afternoon, otherwise the gap between the driver's door and the dash would be the same as the gap between the passenger's door and the dash. And my rear window wouldn't get damp inside. And the console wouldn't squeak. And I wouldn't wonder what exactly that black plastic cap is that fell out of my dashboard.
I know this forum isn't about the Avalon, but I do agree. Our 97 Avalon was nice, but it had some strange quality issues. For example, the power window switch panel kept leaping out of the door and hanging by the wires. The dealer tried to fix it but it never did fit tight. Having shared that, in my humble opinion this was a design failure and had nothing to do with the country where it was built. Ironically the power window motor in the driver's door later failed. Motor probably shorted from the wires dangling out... 

Joined: Feb 2001
Posts: 31,944
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From: North Carolina
Wilson, no offense intended with this observation... Based on your original post wording and replies here you seem to already have your mind made up - you've cherry picked any problem response posts and ignored the positive replies.
I personally suggest you not get one as I suspect you will be hyper-sensitive to looking for the smallest of issues and it will end up being a bad experience for you from the jump.
I personally suggest you not get one as I suspect you will be hyper-sensitive to looking for the smallest of issues and it will end up being a bad experience for you from the jump.
I'm currently exploring other made-in-Japan options. The signature series Mazda 6 looks interesting.
I simply want to go through all the machinations before I buy, not after, like some on the 7-gen ES forum. It would be awful to drop $50K and end up with buyer's remorse. In the end, in part based on the positive responses in this thread, I may very well end up with a 2021 Kentucky-built ES 300h because it is the only affordable luxury hybrid sedan on the market.
When we bought our 2011 Japanese-built ES, I had a blind allegiance to Lexus based on their reputation, and based on three decades of positive experiences with Japanese-built Toyotas. That 2011 ES has been exceptionally reliable! But as you know, the Lexus reputation has been slipping lately, and I was unimpressed with my Kentucky-built Avalon (once burned-twice shy), so this purchasing decision is more difficult. There seems to be a fairly large contingent of CL members who have abandon the Lexus brand altogether, and likely for good reason.
Once I make up my mind, and plunk down the cash, I'm not the type to "be hyper-sensitive, looking for the smallest of issues." All products have issues...luckily I'm adept at resolving them, and retired so I have the time! But, just because I have the time, it doesn't mean I want to be working incessantly on car problems. If I did, I'd buy a German or American brand car!
Agree about the tranny, liked the 6 speed much more...
captain obvious comment: it is very unrealistic to expect flawed humans to build a perfect vehicle let alone building one to a price point. Maybe some drivers are more willing to overlook the issues if they like it enough due some emotional appeal.
This is an astute comment. In all the years I've been buying new cars I haven't found one - not one - that had every feature, system, option, or even design that was perfect and exactly what I wanted. It just doesn't exist. And as Mike states, every car has issues. Some minor, some major. Thankfully, Lexus cars have very few major issues to speak of. At least within my experience and most members of CL.
Agree about the tranny, liked the 6 speed much more...
Agree about the tranny, liked the 6 speed much more...
There is a reason here owners are realizing the difference between the KY and the Japanese built ES's. I have very few issues to nitpick about my Japanese built ES. But when I hear the complaints about quality issues, and the majority of them are coming from cars built in KY, there is some merit in these statements.
Good point. My '19 ES300h was made in Japan. The same goes for my Mazda Miata. That's just my personal preference. I am just hedging my bets those vehicles rolling out from Japan has a higher probability of living up to the Lexus quality.












