The Dakar Rally as an endurance test: Toyota with a hydrogen-electric Hilux

A marathon run to accelerate development. With the DKR GR FC Hilux, Toyota is bringing a hydrogen-electric competition vehicle (FC EV) to the Dakar Rally for the first time. The prototype will compete in 2027 in the experimental ‘Dakar Future Mission 1000’ category. Its mission: to test fuel cell technology under conditions that no conventional test bench can simulate.

The powertrain concept differs fundamentally from a hydrogen internal combustion engine. Two fuel cell stacks convert on-board hydrogen into electrical energy. An electric motor drives the vehicle. The system output is 400 kW (544 PS). Four high-pressure tanks store a total of 8.4 kilograms of gaseous hydrogen. The technology is derived from the Toyota Mirai programme. No direct CO₂ emissions are produced whilst driving; only water comes out of the exhaust. However, the actual carbon footprint depends largely on how the hydrogen is produced.

Tried-and-tested platform, new technology

Toyota has carried over the tubular frame chassis, safety cell, suspension and brakes from the conventionally powered DKR GR Hilux. New features include the electric drive axle, the drive electronics and a special cooling system for the high-voltage system. Toyota is also breaking new ground with the bodywork: natural fibre components partially replace carbon fibre parts.

The prototype is complete and is undergoing intensive testing. It was developed jointly by the Toyota Research Centre near Brussels, Overdrive Racing, Toyota Racing in Cologne and the Toyota Motor Corporation.

Dania Akeel

Foto: toyota

Dania Akeel as test driver

Dania Akeel is at the wheel. The Saudi Arabian knows the Dakar Rally from personal experience: in 2025, she won her first stage in the Challenger category. Now she is set to put the new drive technology through its paces under racing conditions. “It’s a brilliant project where we’re learning more with every kilometre,” says Akeel. She adds that, despite the battery, fuel cells and complex cooling system, the handling is surprisingly similar to that of a conventional Hilux. One challenge remains the lack of acoustic feedback: without engine and gearbox noises, it can sometimes be more difficult to gauge the actual speed.

The Dakar as a rolling development laboratory

With this project, Toyota aims to make fuel cell technology more compact, reliable and efficient. Cooling, durability and energy management, in particular, have yet to prove themselves. The findings are set to be incorporated into future production vehicles and other hydrogen applications.

The project is part of Toyota’s multi-path strategy, which encompasses battery-electric vehicles as well as hybrid, hydrogen internal combustion and fuel cell technology. Gazoo Racing has already gained experience with hydrogen in the Corolla H2 and GR Yaris H2. With the new Hilux, Toyota is now taking things a step further: hydrogen is not burnt, but instead supplies electricity via the fuel cell to power the electric drive.

From 9 to 23 January 2027, the Dakar Rally will pass through Portugal and Morocco – returning to African soil for the first time since 2007. For Toyota, this marks the start of an extraordinary real-world test. The DKR GR FC Hilux is set to demonstrate whether fuel cell technology can hold its own not only on the road, but also in the toughest conditions of everyday rallying.

Beinahe geräuschlos: Der Toyota mit Brennstoffzelle

Foto: toyota