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Lexus ES production ends in Kentucky, making way for Highlander EV

© A. Krivonosov
Lexus ES production in the US ends after a decade, with 440,000 vehicles assembled. The Kentucky plant shifts to the Highlander EV and future electric models.
Michael Powers, Editor

American production of the Lexus ES has come to an end. The final sedan rolled off the line at the Kentucky plant, marking the conclusion of a decade-long run that saw nearly 440,000 vehicles assembled. This project was a landmark for the brand. It was here in 2015 that Lexus, for the first time in its history, began manufacturing vehicles in the United States. The move involved creating a new assembly line, opening 3,750 jobs, and investing around $350 million.

For Toyota, building the ES in America made strategic sense. The model was assembled alongside its platform sibling, the Toyota Camry, placing production close to the sedan's largest market. However, some vehicles continued to be manufactured in Japan, and knock-down kit assembly was planned for India. A shift in the plant's focus had been anticipated for some time. In 2024, Toyota announced a $1.3 billion investment to build a three-row electric crossover. It has now been confirmed that this will be the new Highlander EV, which will replace the ES on the line and become the facility's key project.

The next-generation Lexus ES will be built on a completely different architecture. When showing the model at Auto Shanghai, the company stated that the 2026 version will arrive in the U.S. as either a hybrid or a full electric vehicle. The base hybrid will retain a 2.5-liter internal combustion engine and will be available with both front-wheel and all-wheel drive. The electric lineup includes two variants: the front-wheel-drive ES 350e with 220 horsepower and the dual-motor ES 500e with 338 horsepower. Lexus is targeting a range of 480 km for the front-wheel-drive version and 250 miles for the all-wheel-drive model.

Meanwhile, the plant itself is transitioning to producing hybrid Camry and RAV4 models, as well as future electric vehicles for the brand. Production of the Highlander EV and batteries from North Carolina is set to begin late this year, after which a joint electric model with Subaru will also be introduced.