According to Au7o's analysis of 4,230+ owner reports, the 2001-2025 Toyota Highlander has 51 documented known issues, with 20 rated critical. The most serious are 2GR-FE V6 Excessive Oil Consumption ($0-$4,000 repair), Hybrid Battery Pack Degradation and Failure ($1,500-$5,500 repair), UA80 8-Speed Transmission Whine/Grind — Front Carrier Pinion Shaft Failure ($0-$12,000 repair), Denso Low-Pressure Fuel Pump Failure Causing Engine Stalling (Recall 20V-012) ($0-$800 repair), 2.4L 2AZ-FE Head Gasket and Head Bolt Thread Failure ($2,500-$5,000 repair), 2GR-FE V6 Oil Leak (Timing Cover and Oil Cooler Line) ($300-$4,000 repair), Cluster Fails to Show Speedometer and Brake/Tire Pressure Warnings After Start (Recall 25V595000), Electric Power Steering ECU Damaged in Manufacture — Sudden Loss of Steering Assist (Recall 15V144000) ($0-$1,800 repair), . at .
Gulf States Toyota, Inc. (GST) is recalling certain 2022-2024 model year Highlander L and Highlander LE vehicles equipped with the Blackout Package that includes 20" black alloy wheels and tires. The installed tires have an insufficient load rating. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard number 110, "Tire Selection and Rims."
Campaign #24V41900006/06/2024
TIRES
Southeast Toyota Distributors, LLC (SET) is recalling certain 2021-2024 Highlander vehicles. The 20-inch accessory tires with an insufficient load rating for the vehicle's Gross Axle Weight Rating (GAWR) were installed. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard number 110, "Tire Selection and Rims."
Campaign #24V45200018/06/2024
EQUIPMENT:OTHER:LABELS
Gulf States Toyota, Inc. (GST) is recalling certain Toyota 2023 GR Supra, 2024 4 Runner, Corolla, Grand Highlander, Grand Highlander Hybrid, Land Cruiser Hybrid, Tacoma, Tacoma Hybrid, 2023-2024 BZ4X, Corolla Cross Hybrid, GR Corolla, GR86, Highlander, Highlander Hybrid, Prius, Prius Prime, Sequoia Hybrid, Tundra, Tundra Hybrid, Venza Hybrid, 2023-2025 Crown, and 2025 Camry Hybrid vehicles equipped with GST accessories. The load carrying capacity modification label may display inaccurate added weight values. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard number 110, "Tire Selection and Rims."
🔧
A mechanic who knows YOUR exact car
Answers tuned to your year, make, model & trim — not generic advice. Save your garage so it always has the right context.
Get ahead of Toyota Highlander problems — free
Leave your email and we'll alert you the moment there's a new recall or known issue for your Toyota Highlander. Free, no account needed.
What are the most common Toyota Highlander problems?
According to Au7o's analysis of 4,230+ owner reports, the 2001-2025 Toyota Highlander has 51 documented issues. The most frequently reported are: 2GR-FE V6 Excessive Oil Consumption, Hybrid Battery Pack Degradation and Failure, UA80 8-Speed Transmission Whine/Grind — Front Carrier Pinion Shaft Failure. Of these, 20 are rated critical and should be addressed promptly.
Is the Toyota Highlander reliable?
The 2001-2025 Toyota Highlander has 51 known issues documented across 4,230+ owner reports. 20 issues are rated critical: 2GR-FE V6 Excessive Oil Consumption and Hybrid Battery Pack Degradation and Failure and UA80 8-Speed Transmission Whine/Grind — Front Carrier Pinion Shaft Failure and Denso Low-Pressure Fuel Pump Failure Causing Engine Stalling (Recall 20V-012) and 2.4L 2AZ-FE Head Gasket and Head Bolt Thread Failure and 2GR-FE V6 Oil Leak (Timing Cover and Oil Cooler Line) and Cluster Fails to Show Speedometer and Brake/Tire Pressure Warnings After Start (Recall 25V595000) and Electric Power Steering ECU Damaged in Manufacture — Sudden Loss of Steering Assist (Recall 15V144000) and Second-Row Seat Back May Fail to Lock (Recall 26V-128) and 2GR-FE VVT-i Oil Supply Hose Rupture — Sudden Oil Loss (Service Campaign LSC 90K) and Incorrect Front Seat Trim Covers Block Seat-Mounted Side Air Bag Deployment (Recall 20V633000) and Third-Row Center Seat Belt Roof Anchor Installed at the Wrong Angle (Recall 25V872000) and Occupant Classification System (OCS) Sensor Short Circuit — Front Passenger Air Bag Will Not Deploy (Recall 23V865000) and Hybrid Inverter Intelligent Power Module (IPM) Transistor Solder Failure — Hybrid System Shutdown/Stall (Recall 13V396000) and Steering Column Spiral Cable Weld Separation — Driver's Air Bag Deactivated (Recalls 23V480000 and 25V040000) and Hybrid Inverter Coolant Pump Failure (Inverter Overheat) — P0A05 / P0A93 and Hybrid Brake Booster / ABS Actuator Assembly Failure (Accumulator Leak) — C1391 and Radiator Internal Transmission-Cooler Failure — ATF/Coolant Cross-Contamination ("Strawberry Milkshake") and V6 Engine Oil Sludge / Gelling (1MZ-FE / 3MZ-FE) — Oil Pump Pickup Starvation and 1AR-FE 2.7L Four-Cylinder Excessive Oil Consumption (Low-Tension Ring / Carbon Buildup). Prospective buyers should inspect for these issues and factor potential repair costs into their purchase decision. Regular maintenance following the manufacturer's schedule helps prevent many common problems.
How much does it cost to fix common Toyota Highlander problems?
Content on this page was compiled with AI assistance using NHTSA complaints, TSBs, owner reports, and public automotive data. While we strive for accuracy, this information may contain errors. Always verify repair procedures and specifications with your vehicle's service manual or a qualified mechanic.
Filter:
Community reported
1,850 owners
The 3.5L 2GR-FE V6 in 2nd-gen Highlanders consumes oil excessively, often 1 quart per 1,000-2,000 miles. The root cause is piston ring design allowing oil past the rings into the combustion chamber.
Common Symptoms
Oil level drops between changes
Blue smoke from exhaust on acceleration
Need to add oil every 1,000-2,000 miles
Fouled spark plugs
How to Fix
Perform Toyota oil consumption test at dealer. If consumption exceeds 1 qt/1,200 miles, piston ring replacement is warranted under Toyota's warranty extension (ZE7/ZLG). Short block replacement may be needed in severe cases. Use 0W-20 synthetic and monitor levels closely.
High Confidence1,850 owner reportsLast reported by owners Feb 2026Reviewed Feb 2026
The 2001-2007 Highlander with the 2.4L 2AZ-FE 4-cylinder engine suffers from a design flaw where the aluminum head bolt threads strip out of the engine block. The plastic intake manifold traps heat against the block, causing thermal fatigue of the aluminum threads. This leads to head gasket failure, coolant leaks, and overheating. In severe cases, the stripped threads make a simple head gasket replacement impossible, requiring thread repair inserts (Time-Serts) or complete engine replacement. This is a known issue across Toyota vehicles using the 2AZ-FE engine.
The 3.5L 2GR-FE V6 in the 2008-2013 Highlander develops two significant oil leak patterns. The timing cover sealant fails over time, causing a slow but persistent oil leak from the front of the engine that worsens progressively. More critically, the rubber oil cooler hose can rupture catastrophically, causing rapid oil pressure loss and potential engine damage from oil starvation. Toyota extended the oil cooler hose warranty to 10 years/150,000 miles under a limited service campaign. The timing cover repair requires engine removal and is a major job ($2,000-4,000), while the oil cooler line replacement is more straightforward ($300-800).
On 2GR-FE 3.5L V6 engines (built up through roughly April 2008), the rubber center section of the oil supply hose that feeds the VVT-i actuator degrades from exposure to corrosive PCV gases. A pinhole forms and expands, then the hose bursts, dumping engine oil rapidly. Owners report a sudden loss of oil pressure — sometimes total oil loss within minutes — with severe engine damage if the driver keeps going. Toyota addressed it with Limited Service Campaign 90K (a goodwill campaign, not a safety recall). Notably, the first revised rubber replacement hose was also failure-prone; the durable fix is the all-metal line.
Common Symptoms
Sudden large oil leak / oil sprayed in engine bay
Oil pressure light illuminates
Abnormal engine noise (ticking/knocking) as oil drops
Rapid loss of oil on dipstick
How to Fix
Replace the rubber VVT-i oil hose with the all-metal supply line (Genuine Toyota PN 15772-31030), along with the required banjo/crush gaskets (90430-16017 and 90430-16016). This is the community-recommended permanent fix because both the original and first-revision rubber hoses can fail again. If the hose already burst and the engine ran low on oil, inspect for bearing/cam damage.
What you need to fix it
Only diagnosis- and fitment-reviewed repair parts are linked here.
Toyota 15772-31030 genuine VVT oil pipe
all-metal replacement oil pipe when the confirmed VVT oil-supply-line branch has the failure Fitment/availability: Only a VIN- and production-date-confirmed 2008 Highlander 3.5L 2GR-FE configuration whose current Toyota catalog calls for…
The early Highlander 3.0L 1MZ-FE (and successor 3.3L 3MZ-FE) V6 is prone to engine oil sludge/gelling. Blow-by gases and moisture that fail to burn off (aggravated by short-trip driving, extended oil intervals and a PCV valve that clogs) turn the oil to a gel that coats the valvetrain and, critically, blocks the oil pump pickup screen. Loss of oil pressure follows, leading to bearing/cam wear and catastrophic engine failure. Toyota faced enough claims that it created a sludge-repair goodwill program covering the 3.0L V6 for up to 8 years for owners who could show reasonable maintenance.
Common Symptoms
Oil pressure warning light
Engine knocking/ticking from valvetrain
Blue smoke / high oil consumption
Rough idle and check engine light
Thick, jelly-like sludge under oil cap or on dipstick
How to Fix
Prevention is key: strict 5,000-mile (or shorter for short-trip use) oil changes with the correct spec oil and proactive PCV valve replacement. If sludge is present, remove the oil pan and valve covers to physically clean the pickup screen and galleries; severe cases with spun bearings or scored cams require a rebuilt/replacement engine. Owners with documented maintenance should pursue the Toyota sludge goodwill coverage where still applicable.
What you need to fix it
Only diagnosis- and fitment-reviewed repair parts are linked here.
Toyota 12204-20020 genuine PCV valve
replace a restricted or stuck early-branch PCV valve after inspection Fitment/availability: VIN- and valve-cover-confirmed 2001-2002 Highlander 1MZ-FE early branch Fitment/availability: Live direct product page showing a 1-3 business-day…
alternate PCV branch when testing or sludge cleanup identifies restriction Fitment/availability: VIN- and valve-cover-style-confirmed 2001-2006 Highlander 1MZ-FE or 3MZ-FE branch; overlap with the early valve requires catalog confirmatio…
Toyota 15104-20020 genuine engine oil pickup strainer
replace only if the pickup remains restricted, damaged or cannot be reliably cleaned Fitment/availability: VIN- and engine-diagram-confirmed 1MZ-FE/3MZ-FE Highlander branch; seller catalog spans other Toyota applications Fitment/availabi…
Toyota 11213-0A010 genuine cylinder-head-cover gasket
reseal the corresponding valve cover after removal for sludge inspection and cleaning Fitment/availability: VIN-confirmed 1MZ-FE/3MZ-FE bank and cover configuration; this is one side, not a complete V6 set Fitment/availability: Live dire…
Toyota 11214-0A010 genuine cylinder-head-cover gasket
reseal the second valve cover after removal for sludge inspection and cleaning Fitment/availability: VIN-confirmed 1MZ-FE/3MZ-FE opposite-bank cover configuration; confirm diagram before ordering Fitment/availability: Live direct product…
The four-cylinder 1AR-FE 2.7L offered on the base second-gen Highlander is notorious for burning oil, especially when owners follow Toyota's 10,000-mile oil-change interval. The engine uses low-tension piston rings for fuel economy, and carbon buildup clogs the oil-control ring grooves/drain slots so oil gets past the rings and is burned. Owners report severe rates — a quart every 500-900 miles in bad cases — which can run the engine low enough to trip the oil pressure/low-oil light and risk damage. Distinct from the V6 and 2AZ-FE issues already documented.
Common Symptoms
Frequent need to add oil between changes
Low oil / oil pressure warning light
Blue smoke from the exhaust
Fouled spark plugs
Engine runs low on oil with no visible leak
How to Fix
Confirm the consumption rate with a documented oil-consumption test (dealers historically used a ~1 qt/1,200 mi threshold). Remedies range from shortening oil changes to ~5,000 miles, to a piston-soak/ring-decarbon procedure, up to replacing the piston rings (and sometimes pistons) if rings are carbon-locked. Use the correct 0W-20 spec. A ring/piston job is labor-intensive (commonly $1,500-$3,500); decarbon/soak and a maintenance-interval change are the cheaper first steps. Check the dash/oil light frequently to avoid running it dry.
What you need to fix it
Only diagnosis- and fitment-reviewed repair parts are linked here.
Toyota 13011-36061 genuine standard piston ring set
standard-size replacement ring set for a measured engine rebuild after diagnosis confirms ring sticking or wear—not a maintenance product or substitute for cylinder inspection Fitment/availability: 2009-2013 Highlander 2.7L 1AR-FE only a…
The 2.4-litre turbocharged T24A-FTS that replaced the V6 in the 2023 Highlander produces a distinct low-speed driveability complaint that the 2GR-FKS cars do not have: the vehicle surges and bucks under light and part throttle, typically between about 20 and 45 mph and in the 1,200-2,000 rpm lugging range, with a hesitation on tip-in followed by an abrupt catch-up. It is the single largest owner-reported complaint on the fourth-generation turbo cars and fills multi-hundred-post threads on ToyotaNation. The root of it is calibration: the engine runs an 11:1 compression ratio and is tuned by Toyota for 87 octane regular fuel, where the same T24A-FTS in Lexus applications is specified on 91 octane and draws far fewer complaints. Toyota issued a powertrain ECU recalibration bulletin (T-SB-0087-23); owners consistently report the surging clears immediately after the reflash. Does not apply to the 2GR-FKS V6 or to the hybrid.
Common Symptoms
Surging and bucking under light throttle at 20-45 mph
Hesitation on tip-in followed by a sudden surge
Jerking at low rpm in higher gears
Sensation of the transmission hunting or the lockup clutch cycling
Improves noticeably on 91 octane fuel
How to Fix
Have the dealer apply the powertrain ECU recalibration in Toyota TSB T-SB-0087-23 — it is a software flash, performed free under the powertrain warranty, and owners report it resolves the surging on the same visit. If the surging persists after the flash, running higher-octane (91) fuel measurably reduces it, since the engine's compression ratio is really premium-fuel territory. Rule out the usual mechanical suspects (spark plugs, a slipping torque-converter lockup schedule, a dirty MAF) only after the calibration is confirmed applied.
Highlanders develop random/multiple-cylinder misfires (P0300) plus single-cylinder misfire codes from a cluster of common causes: failing ignition coils, worn spark plugs, a failing PCV valve creating a vacuum leak, and upper intake plenum gasket leaks (especially after a spark-plug job where the intake was disturbed). On the D-4S 2GR-FKS (2017+), carbon buildup on the direct injectors and intake valves can also disrupt the spray pattern and cause misfires. The rough idle and stumble are among the most-searched Highlander complaints. A flashing CEL during a misfire risks catalytic-converter damage.
Common Symptoms
Rough or shaky idle
Hesitation / stumble under acceleration
Flashing or steady check engine light
Reduced fuel economy
Smell of unburned fuel
How to Fix
Diagnose which cylinder(s) by reading codes; swap/replace the suspect ignition coil and replace plugs as a set with the correct iridium plugs at the proper gap. Inspect and replace a failed PCV valve and reseal/replace the upper intake plenum gasket if a vacuum leak is found. On the 2GR-FKS, a fuel-injection/intake-valve carbon cleaning can restore the spray pattern. Coils run ~$40-$120 each, a plug set + labor ~$150-$400; an intake gasket reseal adds labor. Do not keep driving with a flashing misfire light.
What you need to fix it
Only diagnosis- and fitment-reviewed repair parts are linked here.
Toyota 90919-A2005 genuine ignition coil
replace the cylinder-specific coil only after swap or scope testing proves it fails Fitment/availability: VIN-confirmed 2008-2019 Highlander 1AR-FE, 2GR-FE or 2GR-FKS branch; replaces 90919-02256/02255/A2003 Fitment/availability: Live di…
Toyota 90919-01247 genuine FK20HR11 iridium spark plug
correct older-engine plug when wear, fouling or service interval supports replacement Fitment/availability: VIN-confirmed 2008-2016 Highlander 1AR-FE 2.7L or 2GR-FE 3.5L branch; quantity four or six by engine Fitment/availability: Live d…
Toyota 90919-01263 genuine FK20HBR8 iridium spark plug
D-4S-engine plug when inspection or scheduled service supports a set replacement Fitment/availability: VIN-confirmed 2017-2019 Highlander 2GR-FKS 3.5L branch within this record; quantity six Fitment/availability: Live direct product page…
replace only when PCV flow, sealing or hose inspection proves a fault Fitment/availability: VIN-confirmed 1AR-FE 2.7L Highlander branch; reviewed 2013 NAP catalog identifies this valve for ASU40 Fitment/availability: Live direct product …
older V6 PCV replacement only after testing identifies a stuck, restricted or leaking valve Fitment/availability: VIN-confirmed 2GR-FE 3.5L Highlander branch; exact year/build must follow the ventilation-hose diagram Fitment/availability…
later V6 PCV replacement after vacuum/flow diagnosis Fitment/availability: VIN-confirmed later 2GR-FKS 3.5L branch within 2017-2019; do not use it for the older 2GR-FE or 1AR-FE branches Fitment/availability: Live direct product page ind…
Toyota 17176-31040 genuine air-surge-tank gasket set component
reseal the air-surge tank only when removed or when smoke testing proves leakage at this joint Fitment/availability: VIN-confirmed 2008-2011 Highlander 2GR-FE JPP branch; replaced by 17176-0P021 and not valid across the whole issue range…
The 3.5L V6 valve cover gaskets and integrated spark-plug tube seals harden and leak with age. Externally the oil weeps and bakes on the block; internally, oil seeps down the spark-plug tubes and pools around the coil-on-plug boots, fouling the plugs and corroding the coils and causing misfires. The rear (Bank 1, firewall side) valve cover is labor-intensive because the intake manifold must be removed for access, so the leak is often ignored until it causes running issues.
Common Symptoms
Burning oil smell / smoke off the engine
Oil pooled in spark-plug wells
Rough idle, hesitation, misfire
Check engine light (misfire codes)
Visible oil weep on valve covers
How to Fix
Replace both valve cover gaskets and the spark-plug tube seals as a set (Genuine right/Bank-side valve cover gasket 11213-0P030; do both banks since they age together). Clean oil from the tubes, and replace any oil-fouled spark plugs and damaged ignition coils. Doing both covers at once saves the duplicated intake-removal labor.
What you need to fix it
Only diagnosis- and fitment-reviewed repair parts are linked here.
Toyota 11213-31050 genuine cylinder-head-cover gasket No. 1
replacement seal for a confirmed No. 1 cylinder-head-cover gasket leak Fitment/availability: VIN-confirmed 2008-2016 Highlander 3.5L 2GR-FE No.
Toyota 11214-31020 genuine cylinder-head-cover gasket No. 2
replacement seal for a confirmed No. 2 cylinder-head-cover gasket leak or an inspected same-visit reseal Fitment/availability: VIN-confirmed 2008-2016 Highlander 3.5L 2GR-FE No.
replacement seal for plug wells proven to have oil intrusion while the cover is removed Fitment/availability: VIN-confirmed 2008-2016 Highlander 3.5L 2GR-FE serviceable tube-seal branch; order the repair-manual quantity and verify packag…
Toyota recalled approximately 550,007 model-year 2021-2024 Highlander and Highlander Hybrid SUVs (NHTSA 26V-128) because the second-row seat-back recliner teeth may not fully engage when the seat back is adjusted, due to a supplier design change to the recliner guide/ratchet combined with spring orientation and clearance. A seat back that is not securely locked can fail to properly restrain occupants in a crash, increasing injury risk.
Common Symptoms
Second-row seat back does not stay locked after adjusting
Seat back moves or folds unexpectedly
Recliner does not 'click' into a firm locked position
Seat back feels loose when pushed
How to Fix
Under recall 26V-128, dealers replace the return springs in the second-row seat-back recliner assemblies free of charge. Owner notification letters were scheduled to mail around April-May 2026. Owners should verify the seat back clicks firmly into its locked detent and have the recall performed; until repaired, ensure the seat back is fully upright and latched before transporting rear passengers.
Approximately 3,121 model-year 2020 Highlander and Highlander Hybrid vehicles were built with incorrect trim covers on one or both front seats. The seat-mounted side air bag deploys through a tear seam in the seat trim; a cover without the correct seam construction can suffocate or misdirect the deployment, so the side air bag may not deploy properly (or at all) in a side impact. Because this is a build-line trim error rather than a component failure, there is no warning light and no symptom an owner can detect — the only way to know is a VIN check. It affects only early 2020-build XU70 vehicles.
Common Symptoms
No owner-detectable symptom — no warning light
Side air bag fails to deploy in a side-impact crash
Seat side bolster trim seam appears different side-to-side
How to Fix
Free recall remedy under NHTSA 20V633000 — dealers inspect both front seats and replace the seat trim covers as necessary at no charge. Because this recall is small and silent, any used 2020 Highlander should have its VIN run at nhtsa.gov/recalls before purchase; aftermarket seat covers installed over the front seats can independently defeat side air bag deployment and should be removed.
On certain 2024-2025 Highlander and Highlander Hybrid vehicles the roof anchor for the third-row center seat belt was installed at an incorrect angle during assembly. A shoulder-belt anchor that sits at the wrong angle can let the webbing load improperly in a crash, so the belt may not restrain the third-row center occupant as designed — a meaningful risk on a three-row family vehicle where that seat is often used by a child. This is an XU70 assembly defect and is separate from the second-row seat-back latch recall and from the load-capacity label recall already documented for this generation.
Common Symptoms
Third-row center shoulder belt sits at an odd angle across the occupant
Belt webbing twists or rubs at the roof anchor
Belt retracts poorly or binds in the anchor
No warning light — defect is visual/structural only
How to Fix
Free recall remedy under NHTSA 25V872000 — dealers inspect the third-row center belt roof anchor and correct or replace the installation at no charge. Owners should verify the VIN at nhtsa.gov/recalls and avoid seating a passenger in the third-row center position until the inspection is done.
The front passenger seat on 2020-2022 Highlander and Highlander Hybrid vehicles carries an Occupant Classification System sensor mat that weighs the occupant and tells the air bag control module whether — and how hard — to fire the passenger air bag. Improperly manufactured sensors can develop an internal short circuit, so the system can no longer classify the occupant's weight correctly and the front passenger air bag may not deploy as designed in a crash. Owners typically see the air bag warning light on and the PASSENGER AIR BAG OFF indicator stuck on with an adult seated. Toyota covered the defect under NHTSA 23V865000 (Toyota campaign 22TA03 series); interim owner letters went out February 2024, with final remedy letters mailed October 31, 2024.
Common Symptoms
Air bag / SRS warning light on
PASSENGER AIR BAG OFF light stays lit with an adult in the seat
Passenger air bag status light flickers between on and off
Front passenger air bag does not deploy in a crash
How to Fix
Free recall remedy under NHTSA 23V865000 — dealers inspect and replace the OCS sensor as necessary at no charge. Do not accept a diagnosis of 'reset the OCS calibration' on an affected VIN; the sensor mat itself is the defect. Out of campaign, OCS sensor mat replacement plus seat disassembly and re-zeroing is a substantial job.
An electrical connection inside the steering-column spiral cable (clock spring) assembly on certain 2023 Highlander and Highlander Hybrid vehicles was insufficiently welded at the supplier. Over time and with normal steering-wheel rotation the connection can separate, breaking the circuit to the driver's air bag inflator. The air bag is then deactivated and will not deploy in a crash. Toyota first addressed this under recall 23V480000; it later determined that some vehicles repaired under that campaign were incorrectly repaired and issued a second recall, 25V040000, covering roughly 1,700 vehicles across Corolla, Corolla Cross, Highlander, Tacoma and several Lexus lines. Owner letters for the follow-up campaign went out March 17, 2025. Because this is a fourth-generation-only (XU70) supplier defect it does not apply to earlier Highlanders.
Common Symptoms
SRS / air bag warning light illuminated
Horn or steering wheel controls intermittently inoperative
Cruise control or audio steering-wheel switches stop working
Driver's air bag fails to deploy in a crash
How to Fix
Free recall remedy. Dealers inspect and, where necessary, replace the steering column spiral cable assembly at no charge under 23V480000 and — critically — under the follow-up campaign 25V040000 if the first repair was done incorrectly. Owners whose car was already 'fixed' under 23V480000 must still have the VIN re-checked. An air bag warning light on a 2023 car should never be dismissed as a seat-sensor nuisance until the spiral cable is ruled out.
NHTSA recall 25V744000 applies to 2023-2025 Toyota Highlander models equipped with the Panoramic View Monitor. Toyota reports a software error capable of freezing the rearview camera image or blanking the display entirely when the driver shifts into reverse. Since a required rear image is not shown, the Highlander does not comply with FMVSS 111, "Rear Visibility." Toyota's stated consequence is that a rearview camera failing to display an image reduces the driver's view behind the vehicle and increases the risk of a crash - a real concern on a three-row family SUV with a long rear overhang. The 1,024,407 units NHTSA cites is the campaign-wide total across all makes and models involved.
Common Symptoms
Frozen rearview camera image in reverse
Blank display when backing up
Panoramic View Monitor rear view does not appear
How to Fix
Have a Toyota dealer install the updated parking assist software - the repair is free and is the complete remedy for this recall (Toyota numbers 25TB13 and 25LB06). Owner notification letters were mailed January 2, 2026. Check your Highlander's VIN at nhtsa.gov/recalls, or call Toyota customer service at 1-800-331-4331.
On 2020-2022 Highlander Hybrid vehicles the Skid Control ECU software does not turn Vehicle Stability Control back on when the vehicle is restarted after the driver has manually switched VSC off. The car therefore restarts with stability control still disabled, which does not comply with FMVSS 126 — the driver believes VSC is active because the dash indicator behaviour is not what they expect, and the car has no yaw intervention in an emergency manoeuvre. The recall (NHTSA 22V239000, Toyota 22TA03) covered 458,054 vehicles across Toyota and Lexus lines including the Highlander Hybrid; owner letters were mailed May 27, 2022. This is a software non-compliance, not a hardware failure, and is unrelated to the hybrid ABS/brake actuator accumulator fault.
Common Symptoms
VSC remains off after the vehicle is restarted
VSC OFF indicator behaviour inconsistent with driver input
No traction/stability intervention on slippery surfaces
Wheel spin or yaw with no system intervention
How to Fix
Free recall remedy under NHTSA 22V239000 — dealers reflash the Skid Control ECU software at no charge. Until the update is applied, avoid using the VSC OFF switch at all; if it has been used, cycle it back on manually before driving rather than assuming a restart restores it.
Owners of Toyota Safety Sense-equipped Highlanders frequently report the windshield cracking easily from minor stone chips, and the replacement is far more involved and expensive than a traditional windshield because the forward camera below the rearview mirror (used for pre-collision braking and lane-keep) must be recalibrated. Improper replacement glass or a botched recalibration leaves Pre-Collision System, Lane Departure Alert, and auto-high-beam warnings, and some owners have had the camera damaged during the job requiring full camera replacement, not just recalibration.
Common Symptoms
Windshield cracks from small chips
Pre-Collision / Lane Departure warning lights after glass replacement
Auto high-beam or radar-cruise faults
Camera calibration error messages
How to Fix
Use OEM or OEM-equivalent glass with the correct camera bracket/openings, and ensure the shop performs the required static/dynamic Safety Sense camera recalibration after installation. Confirm in advance the shop can recalibrate (some can do glass + recalibration in one visit). Expect roughly $350 with aftermarket glass and recalibration up to $1,000+ with genuine Toyota glass; budget extra if the camera itself must be replaced. After install, verify no TSS warning lights remain.
What you need to fix it
Only diagnosis- and fitment-reviewed repair parts are linked here.
Toyota 56101-0E610 genuine windshield glass sub-assembly
OEM windshield for the exact base configuration before required ADAS calibration Fitment/availability: VIN-confirmed 2020-2024 Highlander base/no-rain-sensor glass branch; confirm all camera, heater, acoustic and mirror options Fitment/a…
Certain 2023-2024 Toyota Highlander and Highlander Hybrid three-row SUVs distributed by Gulf States Toyota (GST) with GST-installed accessories left the distributor with a load carrying capacity modification label that may display inaccurate added weight values. That label exists to subtract the weight of dealer-added equipment from the vehicle's rated capacity, so an incorrect number means the Highlander does not meet Federal Motor Vehicle Safety Standard No. 110, "Tire Selection and Rims." NHTSA warns that a vehicle showing an incorrect maximum capacity weight may be overloaded, which can increase the risk of a crash — a realistic concern in a family SUV routinely loaded with seven or eight occupants plus luggage. The 33,848-unit figure NHTSA lists is campaign-wide across every Toyota model in the recall.
Common Symptoms
How to Fix
GST will mail replacement load carrying capacity labels to owners free of charge; notification letters were mailed September 16, 2024. There is no shop work required — you affix the corrected label and load the Highlander to the corrected figure. Verify whether your specific VIN is covered at nhtsa.gov/recalls, or contact GST customer service at 1-800-444-1074 and cite recall 24R2.
Highlander Hybrid NiMH battery packs degrade over time, with individual cells failing after 8-12 years or 150,000+ miles. Failed cells cause reduced fuel economy, loss of hybrid assist, and eventual inability to start the vehicle.
Common Symptoms
Triangle warning light on dashboard
Reduced fuel economy
Loss of EV mode and hybrid assist
P0A80 Replace Hybrid Battery Pack code
Vehicle struggles to start
How to Fix
Replace the hybrid battery pack. OEM replacement from Toyota is $3,500-$5,500 installed. Refurbished packs from specialists like Green Bean Battery ($1,500-$2,500) or Dorman remanufactured (part 587-004) are more affordable. Individual cell replacement is possible for DIY owners using load-tested cells.
What you need to fix it
Only diagnosis- and fitment-reviewed repair parts are linked here.
Greentec Auto 2006-2009 Highlander Hybrid battery with new cells
new-cell complete-pack option installed by a trained hybrid technician after pack failure is diagnosed; page states a 36-month unlimited-mileage warranty subject to current terms Fitment/availability: 2006-2009 Toyota Highlander Hybrid t…
Greentec Auto 2006-2009 Highlander remanufactured Hybrid battery
lower-cost remanufactured complete-pack option; page states an 18-month unlimited-mileage warranty subject to current terms and original service purchased Fitment/availability: 2006-2009 Toyota Highlander Hybrid traction-battery branch o…
Greentec Auto 2010-2016 Highlander Hybrid battery with new cells
new-cell complete-pack option for the second battery architecture after professional diagnosis and installation Fitment/availability: 2010-2013 portion of this issue's Highlander Hybrid range; product also covers later years, but the dis…
Greentec Auto 2010-2016 Highlander remanufactured Hybrid battery
remanufactured complete-pack alternative for the second battery architecture, installed by a trained hybrid technician Fitment/availability: 2010-2013 portion of this issue's Highlander Hybrid range; verify VIN, diagnosis, service area, …
High Confidence1,200 owner reportsLast reported by owners Feb 2026Reviewed Feb 2026
2023-2025 Highlanders are among the vehicles named in NHTSA recall 25V595000. Toyota reports an error in the instrument panel software that occurs at vehicle startup; when it happens, the instrument panel may fail to display vehicle speed along with the brake system and tire pressure warning lights. For a family three-row like the Highlander this matters twice over: you lose your speed reference, and you also lose the two telltales that would warn you about a brake system fault or a low tire before a long drive. NHTSA's stated consequence is that a display not showing critical information can increase the risk of a crash or injury. The 591,377-vehicle figure quoted for this recall is the total for the entire campaign across all affected Toyota and Lexus models, not a Highlander-specific count.
Common Symptoms
No vehicle speed shown on the instrument panel after starting the vehicle
Brake system warning light missing from the display
Tire pressure warning light missing from the display
How to Fix
Free of charge. Non-PHEV Highlanders receive an over-the-air instrument panel software update from Toyota; a dealer can apply the update if the OTA does not complete. Toyota mailed the first owner letters December 5, 2025, and because the recall is phased, further letters are anticipated in May 2026. Check your VIN at nhtsa.gov/recalls to see if your Highlander is covered and whether the fix has already been performed. Toyota customer service: 1-800-331-4331 (campaign numbers 25TB08 and 25TA08).
On the first- and second-generation Highlander Hybrid (2GR-FXE / 3MZ-FE hybrid), the Intelligent Power Module inside the hybrid inverter assembly carries control-board transistors whose operating temperature can exceed what the solder beneath them tolerates. The solder degrades, the transistor is heat-damaged, and the hybrid system throws multiple warning lamps. In most cases the vehicle drops into fail-safe/limp-home mode with sharply reduced power; in worse cases the power-supply-circuit fuse blows and the entire hybrid system shuts down while driving, stalling the vehicle. This is distinct from the inverter coolant pump failure and from HV traction-battery degradation — here it is the power electronics themselves, not the cooling loop or the pack. Toyota first recalled 2006-2007 cars (11V342000) and then broadened it to all 2006-2010 Highlander Hybrids built Feb 2005 through Jul 2010 under 13V396000 / Toyota campaign D0M.
Common Symptoms
Multiple warning lights on at once — check engine, slip indicator, brake system, master warning
Sudden loss of power / limp-home mode
Hybrid system shuts down and vehicle stalls while driving
Vehicle will not restart after shutdown
Reduced acceleration, dashboard warning chime
How to Fix
Free recall remedy: dealers replace the Intelligent Power Module inside the inverter assembly at no cost under NHTSA 13V396000 (Toyota D0M) — check the VIN at nhtsa.gov/recalls, because many of these cars have changed hands several times and never had it done. If the VIN is not covered or the campaign has been performed and the fault returns, the repair is inverter assembly replacement (or specialist IPM board rework), which is the expensive path.
The HVAC blower motor in 3rd-generation Highlanders commonly fails or operates intermittently. The blower motor resistor overheats and burns out, causing the fan to work only on the highest speed setting or stop completely. Moisture intrusion through the cabin air filter housing accelerates corrosion.
Common Symptoms
Blower only works on highest speed setting
No airflow from any vent
Burning smell from dashboard vents
Intermittent blower operation
Squealing noise from blower area
How to Fix
Replace the blower motor and blower motor resistor together. Clean any debris from the cabin air filter housing and ensure the drain is clear. An updated resistor design (Toyota part 87138-0E040) has improved thermal management.
Owner tips & cautions
TipAlways replace the resistor when replacing the blower motor - a failed resistor will burn out the new motor.
High Confidence260 owner reportsLast reported by owners Mar 2026Reviewed Mar 2026
Fourth-generation Highlanders and Highlander Hybrids repeatedly kill their 12V battery while parked, sometimes over just a few days and often with a battery only weeks old. Owners on ToyotaNation trace it to modules that never go to sleep: the Data Communication Module (the telematics unit behind Safety Connect / Remote Connect) continuing to search when cell signal is weak, a remote-start component that fails to shut off, kick-sensor and door-switch circuits, and the general low reserve of the small AGM battery the hybrid uses. Toyota has published DCM power-saving software updates for related Toyota models on the same telematics platform. The hybrid is particularly unforgiving because its 12V battery is small and is only recharged when the vehicle is in READY mode — short trips never fully replenish it.
Common Symptoms
Dead 12V battery after the car sits a few days
Brand-new battery goes flat within days
Multiple warning lights and system faults on a weak battery
Vehicle will not enter READY / will not crank
Remote start or connected services behaving oddly before the drain
How to Fix
Measure parasitic draw with a clamp meter or in-line ammeter after the modules time out; normal is under about 50 mA. If draw stays high, pull fuses one at a time to isolate the circuit, checking the DCM/telematics, remote start and door/kick-sensor circuits first, and ask the dealer whether a DCM power-saving software update applies to your VIN. Confirm the battery is the correct spec and fully charged — a hybrid 12V battery that has been deeply discharged repeatedly will not recover and should be replaced. Owners who drive mostly short trips benefit from a maintainer. Disabling remote-start/connected services is a valid diagnostic step to prove the DCM is the drain.
What you need to diagnose it
The fix here starts with a test, not a part — which repair you need depends on what the test finds.
UNI-T UT210E Low-Current DC Clamp Meter
1 mA resolution on the 2 A range — a 0.1 A meter reads a 50 mA drain as zero
As an Amazon Associate, we earn from qualifying purchases. Prices are approximate and may vary.
Testing and isolating the fault is DIY work. Replacing or reprogramming a control module is not — most are VIN-programmed, so a new one does nothing until a shop codes it to your car. Check for an open recall or service bulletin before buying anything.
The Highlander Hybrid cools its high-voltage battery by drawing cabin air through an intake located under the cargo floor, past a filter, through a blower and across the pack. Dust, lint and pet hair progressively clog the filter and cake the fan blades. Airflow drops, cells run hot, block voltages diverge, and the ECU sets P0A80 (replace hybrid battery pack) or P0A7F (hybrid battery pack deterioration) — codes that read like a dead pack. Many owners are quoted a full battery replacement when the actual fault is a clogged filter and dirty fan. Toyota addressed exactly this in a technical service bulletin covering 2006-2019 Highlander Hybrid vehicles, instructing technicians to clean the fan, ducts and filter before condemning the pack. This is a separate failure from genuine pack degradation and from the inverter coolant pump.
Common Symptoms
Check engine light with hybrid battery codes
Hybrid battery cooling fan audibly loud or roaring
Reduced EV assist and worse fuel economy
Warning message about the hybrid system
State-of-charge bar swings rapidly between high and low
How to Fix
Before authorising any hybrid battery replacement, have the HV battery cooling intake (under the cargo floor on Highlander Hybrid), the filter and the blower fan inspected and cleaned per the Toyota bulletin — vacuum the duct and filter and clean the fan blades with compressed air, taking care not to let the fan spin freely, which damages the motor. Clean or replace the filter annually if you carry pets or drive dusty roads, and never block the intake with cargo. If block-voltage spread remains wide after cleaning and re-learning, the pack is genuinely degraded.
Owners report a 'Charging System Malfunction' warning and intermittent hard-start / no-start conditions traced to a failing alternator that no longer maintains battery voltage. A healthy unit should read ~13.5–14.8 V at the battery with the engine running; below ~13 V confirms a charging fault. Because the alternator solely charges the battery, a jump start is only a temporary band-aid and the vehicle strands again once the battery drains.
Common Symptoms
"Charging System Malfunction" warning message
Dim/flickering headlights and slow cranking
Battery warning light
Repeated dead battery / no-start
Electrical accessories act erratically
How to Fix
Load-test the battery and measure charging voltage before condemning parts. If output is low with a good belt/tensioner, replace the alternator (use a quality OEM-grade Denso unit). Inspect the serpentine belt/tensioner and battery cable connections, and replace a weak battery at the same time so the new alternator isn't overworked.
What you need to fix it
Only diagnosis- and fitment-reviewed repair parts are linked here.
Toyota 27060-0P241 genuine 150 A alternator assembly
replacement alternator only after testing proves the 150 A 2GR-FE unit has failed Fitment/availability: VIN-confirmed 2014-2016 Highlander 3.5L 2GR-FE 150 A branch; confirm amperage, connector and current supersession before ordering Fit…
Toyota 27060-0V080 genuine 150 A alternator assembly
replacement alternator only after testing proves the 150 A 1AR-FE unit has failed Fitment/availability: VIN-confirmed 2014-2019 Highlander 2.7L 1AR-FE 150 A branch; do not apply the seller's broad model-level fitment without checking the…
Toyota 27060-31410 genuine 180 A alternator assembly
current replacement alternator for the diagnosed 180 A 2GR-FKS branch Fitment/availability: VIN-confirmed 2017-2020 Highlander gas 3.5L 2GR-FKS 180 A branch that supersedes 27060-0P420; exclude Hybrid and verify engine, amperage and conn…
Toyota 90916-A2026 genuine V-ribbed accessory belt
conditional replacement when inspection finds the alternator-drive belt cracked, glazed, frayed, contaminated or otherwise unserviceable Fitment/availability: VIN-confirmed 2016-2020 Highlander gas branch whose current catalog specifies …
Toyota 16620-0P010 genuine V-ribbed belt tensioner assembly
conditional replacement when inspection or testing proves weak tension, bearing noise, binding or travel failure Fitment/availability: VIN-confirmed 2016-2018 Highlander gas branch only; 2014-2015 and 2019-2020 vehicles require separate …
Third-generation Highlanders with the Entune head unit commonly suffer the multi-function display freezing or going completely blank — the audio cuts out, the touchscreen and side menu buttons stop responding, and sometimes the screen stays dark on startup. Owners report it happening randomly and repeatedly. Toyota issued a Technical Service Bulletin and software updates for Entune lockups, but persistent units sometimes need replacement.
Common Symptoms
Touchscreen unresponsive / frozen
Audio randomly cuts out
Black/blank display at startup
Side menu buttons do nothing
Backup camera image missing on the screen
How to Fix
First try the documented reset: with the system powered on (key/On), press and hold the PWR-VOL knob ~10-12 seconds until it reboots. If it recurs, have the dealer apply the Entune software update / TSB (often free under warranty). For units that still fail, the head unit is replaced/refurbished — owners report ~$800+ for a replacement/refurb display unit, with a 2-3 week turnaround in some cases.
The Highlander Hybrid uses a dedicated electric water pump to circulate coolant through the power inverter/converter, which runs separately from the engine cooling system. The electric pump wears out and stops circulating coolant, allowing the inverter and hybrid electronics to overheat. Failures often present with little warning beyond a check engine light and hybrid warning lights; if ignored, the inverter itself (a far more expensive component) can be damaged. Owners report this most on the 2006-2010 generation but it recurs across later hybrids.
Common Symptoms
Check engine and hybrid system warning lights
Inverter coolant leak / low inverter reservoir
Reduced hybrid power or limp mode
Overheating of the hybrid/inverter system
How to Fix
Replace the inverter cooling electric water pump and refill/bleed the inverter coolant loop (air-bleed procedure is required). For the 2006-2010 Highlander Hybrid the drive-motor inverter cooler water pump is Toyota PN G9040-48080 (non-tow); tow-package and later years use a different pump (e.g., G9020-48xxx family) so verify by VIN/configuration. Expect roughly $700-$1,100 done by a competent shop (pump ~$220-$290 plus diagnosis/labor and coolant). Catch it early — replacing the pump is far cheaper than an overheated inverter.
What you need to fix it
Only diagnosis- and fitment-reviewed repair parts are linked here.
Toyota G9040-48080 genuine drive-motor inverter cooler water pump
early-generation inverter-loop pump after flow and electrical diagnosis proves failure Fitment/availability: VIN-confirmed 2006-2010 Highlander Hybrid MHU23/MHU28 and applicable early MHU48 branch; verify production date and tow/cooling …
Toyota G9040-47090 genuine inverter water pump assembly
middle production branch pump after inverter-loop diagnosis Fitment/availability: VIN- and production-date-confirmed 2010-2013 Highlander Hybrid branch; replaces G9040-48020 on applicable vehicles Fitment/availability: Live direct produc…
Toyota G9040-52020 genuine inverter water pump assembly
late third-generation inverter-loop pump after flow and electrical testing Fitment/availability: VIN-confirmed late-2016 through 2019 Highlander Hybrid 3.5L branch; catalog production change begins 11/2016 Fitment/availability: Live dire…
Automatic-transmission Highlanders route ATF through a cooler integrated into the main radiator end tank. When the internal separator corrodes/cracks, engine coolant and transmission fluid mix, producing a pink 'strawberry milkshake' emulsion. Coolant in the ATF destroys the clutch friction material (it absorbs water and disintegrates), so a radiator failure frequently takes the transmission down with it. Especially common on higher-mileage vehicles and those used for towing.
Common Symptoms
Pink/milky fluid in coolant reservoir or on dipstick
Overheating or fluctuating temperature
Transmission slipping, harsh or erratic shifts
Low coolant with no external leak
Whitish sludge in radiator
How to Fix
Replace the radiator immediately at the first sign of fluid mixing and do NOT keep driving. Flush the transmission and cooler lines thoroughly; if the trans is already contaminated or slipping, a rebuild/replacement is often required. Many owners preventively bypass the in-radiator cooler and install a standalone external transmission cooler, particularly for towing use.
What you need to fix it
Only diagnosis- and fitment-reviewed repair parts are linked here.
Toyota 16410-AZ026 genuine service radiator assembly
earliest branch radiator replacement after internal cooler failure is confirmed Fitment/availability: VIN-confirmed 2001-2004 Highlander non-hybrid configuration replacing applicable 16400-20220/YZZAL service radiator; verify tow package…
Toyota 16400-20330 genuine standard-cooling radiator assembly
first-generation standard radiator with integrated transmission cooler Fitment/availability: VIN-confirmed 2003-2007 Highlander non-hybrid standard-cooling branch; not the tow-package radiator Fitment/availability: Live direct product pa…
Toyota 16400-20340 genuine tow-package radiator assembly
tow/heavy-duty first-generation radiator branch Fitment/availability: VIN-confirmed 2003-2007 Highlander non-hybrid with the factory towing package Fitment/availability: Live direct product page showing Add to Cart and a 1-3 business-day…
Toyota 16041-0P240 genuine radiator assembly No. 2
later second-generation radiator branch after exact catalog match Fitment/availability: VIN-confirmed 2010-2013 Highlander non-hybrid branch; tow-package/current-supersession configurations can use 16041-0P251 and must be checked Fitment…
The engine-driven water pump on V6 Highlanders commonly leaks coolant from its weep hole as the internal seal and bearing wear, typically around 90,000-120,000 miles. Early signs are a pink/green crusty residue or puddle at the front of the engine and sometimes a squeal or whine. Left unaddressed, a failing pump can cause sudden overheating and risk warped heads or engine damage. The pump sits deep in the timing-cover area, making it a labor-intensive replacement.
Common Symptoms
Pink or green coolant crust/puddle at front of engine
Coolant smell or low-coolant warnings
Whining or grinding noise from front of engine
Engine overheating / temperature gauge climbing
Visible drip from water-pump weep hole
How to Fix
Replace the water pump (and gasket) at the first sign of seepage; many shops replace the thermostat and serpentine belt at the same time to save on the substantial labor. Maintain Toyota's ~50,000-mile coolant change interval with SLLC to slow seal/bearing corrosion. Watch the weep hole at each service for the early pink-crust warning.
What you need to fix it
Only diagnosis- and fitment-reviewed repair parts are linked here.
Toyota 16100-09442 genuine water pump assembly
early production water-pump assembly after leak or bearing failure is confirmed Fitment/availability: VIN- and production-date-confirmed early 2014-2017 Highlander V6 branch, principally 2GR-FE; verify plant and supersession Fitment/avai…
later production pump after pressure testing localizes the failure Fitment/availability: VIN- and production-date-confirmed later 2016-2020 Highlander V6 branch including applicable 2GR-FKS builds Fitment/availability: Live direct produc…
required sealing component only for the matching early pump configuration Fitment/availability: VIN-confirmed applicable 2014-2017 Highlander V6 pump branch; later pumps must use the seal specified for that exact assembly Fitment/availab…
optional while-access-is-open replacement when testing, age or condition supports it Fitment/availability: VIN-confirmed applicable 2014-2019 Highlander V6 branch; do not apply to a 2020 inlet-with-thermostat configuration Fitment/availa…
Toyota 90916-A2019 genuine V-ribbed serpentine belt
condition-based early-branch drive-belt replacement while pump access is open Fitment/availability: VIN-confirmed 2014-2017 Highlander V6 branch Fitment/availability: Live direct product page showing a 1-3 business-day ship estimate
Toyota 90916-A2026 genuine V-ribbed serpentine belt
condition-based later-branch drive-belt replacement while pump access is open Fitment/availability: VIN-confirmed 2018-2020 Highlander V6 within this issue; seller catalog begins this belt in 2016, so production confirmation remains requ…
The UA80E/UA80F 8-speed automatic in V6 Highlanders can develop a whine or grind noise traced to defective front carrier assembly pinion shafts/bearings. As the bearings delaminate they shed metal debris through the fluid, which can progressively damage the torque converter and transaxle internals. This is a hard mechanical failure distinct from the more common torque-converter shudder/hesitation driveability complaint, and Toyota's prescribed repair is full transaxle replacement.
Common Symptoms
Whining noise from transmission that rises with vehicle speed
Grinding noise from the transaxle
Metal shavings found in transmission fluid
Eventual harsh shifting or shudder as damage spreads
Complete transmission failure in severe cases
How to Fix
Toyota TSB T-SB-0008-21 covers the whine/grind noise and directs replacement of the transaxle assembly (the pinion shafts are not serviced individually). Repairs are covered under the 5-year/60,000-mile powertrain warranty; out-of-warranty owners have faced $9,000-$12,000 quotes. Early diagnosis and a fluid inspection for metal can catch it before torque-converter contamination spreads.
What you need to fix it
Only diagnosis- and fitment-reviewed repair parts are linked here.
Toyota 30500-0E100 genuine UA80E automatic transaxle assembly
complete FWD transaxle only after the bulletin noise and serial criteria are met Fitment/availability: Bulletin- and production-serial-confirmed 2021 Highlander FWD with UA80E; seller model-year aggregation is broader, so do not use it t…
Toyota 30500-0E160 genuine UA80F automatic transaxle assembly
complete AWD transaxle only after the bulletin noise and serial criteria are met Fitment/availability: Bulletin- and production-serial-confirmed 2021 Highlander AWD with UA80F; verify current supersession by VIN Fitment/availability: Liv…
The Direct Shift 8AT transmission in 4th-gen Highlanders exhibits shudder, hesitation on acceleration, and rough downshifts. The torque converter lockup clutch causes vibration at low speeds, particularly between 25-45 mph.
Common Symptoms
Shudder at 25-45 mph under light throttle
Hesitation on acceleration from stop
Rough downshifts when slowing
Vibration felt through seat and steering wheel
How to Fix
Visit dealer for TCM software update (TSB 0011-21). Transmission fluid drain and refill with Toyota WS ATF may help. Some owners report improvement after the transmission 'learns' driving habits over 5,000+ miles. Persistent cases may need torque converter replacement.
What you need to fix it
Only diagnosis- and fitment-reviewed repair parts are linked here.
Toyota 00289-ATFWS genuine World Standard automatic transmission fluid, 1 quart
correct fluid only when level correction or a repair-manual drain-and-refill is indicated after diagnosis Fitment/availability: VIN-confirmed 2020-2024 Highlander automatic transaxle that specifies Toyota WS; quantity follows the measure…
Medium Confidence920 owner reportsLast reported by owners Feb 2026Reviewed Feb 2026
Certain Highlanders are part of Toyota's large Denso low-pressure fuel pump recall (NHTSA 20V-012). The pump's resin impeller can absorb fuel, swell, and crack, causing the pump to seize. This leads to rough running, hard starting, and engine stalling — potentially at speed and without warning — creating a crash risk. The defect spans many Toyota/Lexus models; the Highlander was specifically named in the campaign.
Common Symptoms
Engine stalls while driving, sometimes at speed
Long crank / hard starting
Rough idle or hesitation
Illuminated check engine light
Engine fails to restart after stalling
Fuel system warning indicators
How to Fix
Under recall 20V-012 (and related expansions), Toyota dealers replace the low-pressure fuel pump assembly with an improved-impeller unit free of charge. Owners should run their VIN at nhtsa.gov or contact Toyota; vehicles showing stalling/hard-start symptoms before the pump is replaced should be inspected promptly.
On 2020-2021 Highlander Hybrids a fuel-tank venting/charcoal-canister defect causes the gas pump's automatic shut-off to trigger prematurely. The advertised 17.1-gallon tank typically accepts only ~12-14 gallons from empty before the nozzle clicks off, and forcing more fuel can cause spillback. This shortens single-tank range well below the rated ~615 miles and the gauge often never reads truly full. A class action (later voluntarily dismissed) and owner reports tie it to inadequate tank venting on the hybrid's bladder-style/double-wall tank.
Common Symptoms
Fuel pump nozzle shuts off after only 12-14 gallons on an empty tank
Fuel spits back / spills when trying to add more
Fuel gauge rarely reads completely full
Driving range much shorter than advertised
Repeated click-offs while refueling
How to Fix
Toyota issued a service bulletin and dealers replaced the fuel tank assembly and fuel sender under warranty, which restored fill capacity to roughly 14.5 gallons (up from ~12). Owners who report the problem during fueling should reference the TSB; using a slow, single-click fueling technique and not topping off mitigates spillback in the interim.
What you need to fix it
Only diagnosis- and fitment-reviewed repair parts are linked here.
Toyota 77001-0E161 genuine updated fuel tank sub-assembly
updated tank required with the sender and bracket only after the bulletin diagnostic criteria are met Fitment/availability: Production-VIN-confirmed plant-code-S 2020-2021 Highlander Hybrid covered by T-SB-0008-22; current part replaces …
Toyota 77173-0E021 genuine updated fuel-gauge bracket
updated bracket installed with the revised tank and sender under the bulletin procedure Fitment/availability: VIN-confirmed 2020-2021 Highlander Hybrid branch covered by T-SB-0008-22; replaces 77173-0E020 Fitment/availability: Live direc…
Toyota 83320-0E061 genuine updated fuel-gauge sending unit
updated sender installed together with the revised tank and bracket Fitment/availability: VIN-confirmed applicable 2020-2021 Highlander Hybrid; replaces TSB-listed 83320-0E060 Fitment/availability: Live direct product page showing a curr…
single-use sealing part required during sender/tank transfer Fitment/availability: 2020-2021 Highlander Hybrid fuel-suction-tube seal specified by T-SB-0008-22; verify VIN and current supersession Fitment/availability: Live direct produc…
The regenerative-braking brake actuator (the integrated ABS/booster/accumulator pump module) is a known weak spot on the Highlander Hybrid. The accumulator develops an internal leak and the pump runs constantly, triggering a loud, repetitive whirring/buzzing and warning lights; in some cases brake assist is reduced, which owners describe as a serious safety concern (the same family of actuators drove early Prius brake recalls). CarComplaints documents repeated brake actuator complaints on the 2006 Highlander Hybrid, and the repair is rarely covered out of warranty.
Common Symptoms
Constant brake pump motor whirring/buzzing
Brake, ABS, VSC and hybrid warning lights
Hard or reduced brake assist
Longer stopping distance
How to Fix
Replace the integrated brake actuator assembly and re-initialize/program it with Toyota Techstream (the new unit must be calibrated and bled). For the 2006-2007 Highlander Hybrid the actuator is Toyota PN 44050-48191; 2008-2013 use 44050-48320 — verify by VIN. This is expensive: the part alone runs ~$1,200-$1,800 and full dealer replacement quotes range from roughly $2,600 to $3,500+. Independent hybrid specialists can be cheaper.
What you need to fix it
Only diagnosis- and fitment-reviewed repair parts are linked here.
Toyota 44050-48191 genuine brake actuator/modulator
first-generation actuator replacement only after Toyota brake-system diagnosis condemns the integrated modulator assembly Fitment/availability: VIN-confirmed 2006-2007 Highlander Hybrid 3.3L MHU23/MHU28 branch; replaces 44050-48190 Fitme…
Toyota 47070-48020 genuine brake-booster pump/accumulator assembly
pump/accumulator replacement when accumulator leakage or pump failure is proven by the Toyota diagnostic procedure Fitment/availability: VIN-confirmed 2008-2011 Highlander Hybrid MHU48 brake-booster-pump branch; use the exact Toyota diag…
Toyota 47070-48060 genuine brake-booster pump assembly
later pump/accumulator replacement after pressure-leak or pump diagnosis proves this assembly failed Fitment/availability: VIN-confirmed 2011-2013 Highlander Hybrid GVU48 brake-booster-pump branch within this record; production-date over…
Toyota 44050-48320 genuine brake actuator assembly
ABS/regenerative brake actuator replacement only when actuator valves, electronics or internal hydraulic functions fail their specific tests Fitment/availability: VIN-confirmed 2008-2013 Highlander Hybrid MHU48/GVU48 actuator branch; do …
Owners report steering-wheel shimmy and brake-pedal pulsation from warped/unevenly-deposited front rotors at surprisingly low mileage (some as early as 10,000–37,000 miles). The mechanism is usually uneven pad-material transfer ('rotor painting') from heat rather than literal warping, but the result is the same vibration. Because Toyota classifies rotors as a wear item warranted only briefly, many owners are denied coverage and pay out of pocket, generating numerous CarComplaints entries.
Common Symptoms
Steering wheel vibration when braking at speed
Brake pedal pulsation
Seat/body shudder under braking (rear rotors)
Vibration worsens as brakes heat up
How to Fix
Machine the rotors if within spec, but replacement is usually the durable fix at this mileage. Install quality rotors and pads, and — critically — torque the wheels to spec in a star pattern and bed the pads properly to prevent recurrence. Address any sticking caliper slide pins that cause localized overheating.
What you need to fix it
Only diagnosis- and fitment-reviewed repair parts are linked here.
Toyota 43512-0E030 genuine front brake rotor
front rotor pair when runout, thickness variation or minimum thickness makes machining unsuitable Fitment/availability: VIN-confirmed 2014-2019 Highlander front axle within this issue; catalog also lists adjacent years, so stay within th…
front axle pad set when pads are worn, tapered, contaminated or being renewed with damaged rotors Fitment/availability: VIN-confirmed 2014-2019 Highlander front pad branch; shims and fitting hardware may be separate Fitment/availability:…
fourth-generation front rotor pair when measured condition requires replacement Fitment/availability: VIN-confirmed 2020-2022 Highlander front axle within this record Fitment/availability: Live direct product page showing Add to Cart and…
fourth-generation front axle pad set when inspection supports replacement Fitment/availability: VIN-confirmed 2020-2022 Highlander front pad branch within this issue; verify gas/hybrid service procedure Fitment/availability: Live direct …
Toyota 47715-04080 genuine front caliper main slide pin
replace a corroded, scored or seized main pin after caliper inspection Fitment/availability: VIN-confirmed 2014-2019 Highlander front caliper branch within this issue; quantity and upper/lower position must follow the exact diagram Fitme…
replace a swollen, hardened, torn or missing slide-pin bushing that prevents free caliper movement Fitment/availability: VIN- and caliper-position-confirmed 2014-2022 Highlander service branch; use the repair diagram because the same bus…
A component inside the electric power steering ECU on certain 2015 Highlander and Highlander Hybrid vehicles was damaged during the manufacturing process. The damage progresses over time and can end in outright failure of the EPS system, meaning the driver loses power assist without warning — the steering does not lock, but the effort required rises abruptly, which is dangerous mid-corner or at parking speeds with a loaded three-row SUV. The recall covered roughly 110,085 vehicles across 2015 Camry, Camry Hybrid, Highlander and Highlander Hybrid plus 2014-2015 RAV4 (NHTSA 15V144000), and the remedy began May 7, 2015. This is XU50-specific and does not describe the hydraulic-rack first-generation cars or the later XU70.
Common Symptoms
Steering suddenly becomes very heavy
EPS / power steering warning light on dash
Intermittent loss of steering assist at low speed
Whine or noise from the steering column
How to Fix
Free recall remedy under NHTSA 15V144000 — dealers read the serial number of the EPS ECU / steering column assembly and, if it falls in the affected range, replace the EPS ECU at no charge. Because the campaign is over a decade old, check the VIN at nhtsa.gov/recalls; recalls do not expire. Out of campaign, EPS ECU or full steering column assembly replacement runs well into four figures.
The power liftgate on second- and third-generation Highlanders (and the Hybrid) is prone to the power lift arm/strut breaking away from the gate, which lets the driver-side hinge bow and can leave the hatch stuck open or unable to latch closed. A class action filed in 2025 (Morgan & Morgan) alleges Toyota has known about the defective liftgate since at least 2010 across the XU20, XU40, XU50 and Hybrid MHU28 platforms but never issued a recall; because the failure usually shows up after warranty, owners report paying near $5,000 out of pocket. Owners also report leaky struts, height-sensor faults that cause partial opening with long beeps, and cold-weather failures.
Common Symptoms
Liftgate stuck open or won't latch closed
Hatch bows or sags on one side
Long beeps and partial opening
Liftgate stops working in cold weather
Struts that no longer hold the gate up
How to Fix
Have the liftgate struts/gas props and the power lift arm actuator inspected; replace failed gas struts in pairs and replace the power lift arm/actuator if it has separated or the hinge is bowed. Many owners with minor faults restore function by cleaning the latch/tracks, realigning or replacing the latch, and resetting the system (disconnect/reconnect the battery, then re-initialize the open/close memory). Strut replacement is inexpensive (roughly $80-$250); a full power lift arm/actuator and hinge repair at a dealer can run well over $1,000.
What you need to fix it
Only diagnosis- and fitment-reviewed repair parts are linked here.
Toyota 85007-09005 genuine power liftgate motor unit
replace only after motor/drive diagnosis and structural inspection exclude or repair hinge/panel damage Fitment/availability: VIN-confirmed 2008-2013 Highlander or Highlander Hybrid with factory power back door; supersedes multiple 85007…
right support replacement when loss of gas support is confirmed; replace the applicable pair for balanced support Fitment/availability: VIN- and option-confirmed 2010-2013 Highlander passenger-side back-door stay; replaces 68950-0E070 an…
left support replacement paired with the correct right stay when supports are weak or leaking Fitment/availability: VIN- and option-confirmed 2010-2013 Highlander driver-side back-door stay; replaces 68960-0E070 Fitment/availability: Liv…
Toyota 68910-09120 genuine right power lift-cylinder/unit assembly
right powered lift cylinder after side-specific actuator failure is confirmed and hinge/panel geometry is sound Fitment/availability: VIN- and production-date-confirmed 2014-2019 Highlander passenger-side powered liftgate branch; replace…
Water pools in the rear cargo area, spare-tire well, and behind the rear interior trim because of leaks at the taillight seals/gaskets and the liftgate/hatch weatherstrip, plus secondary paths through the third (high-mount) brake light, the rear air-deflector/spoiler bracket foam gasket, roof-rack mounts, and clogged sunroof/quarter drains. Left wet, it causes musty smell, mold, corrosion of the hatch and rear electrical connectors, and can fog or kill the backup camera. In salt-belt cars the trapped water accelerates hatch and wheel-arch rust.
Common Symptoms
Water in the spare-tire well or cargo floor
Musty/moldy smell in the back
Wet rear trim panels or carpet
Foggy or failed backup camera
Rust around the hatch or taillights
How to Fix
Find the entry point with a controlled water test. Reseal or replace the taillight gaskets (a frequent culprit), replace the hatch/liftgate weatherstrip if cracked, reseal the third brake light and the rear spoiler/air-deflector bracket foam, and clear clogged drains. Dry the spare-tire well and treat any surface rust. Most fixes are inexpensive seals and labor ($50-$300); ignoring it risks far costlier corrosion and electrical/backup-camera damage.
What you need to fix it
Only diagnosis- and fitment-reviewed repair parts are linked here.
Toyota 67881-48041 genuine back-door weatherstrip
replace only when the body-side hatch seal is proven torn, compressed or leaking Fitment/availability: VIN-confirmed 2008-2013 Highlander JPP/Hybrid branch; NAP catalog can use 67881-0E040, so plant confirmation is mandatory Fitment/avai…
later-generation weatherstrip when controlled water testing proves this perimeter is the path Fitment/availability: VIN-confirmed 2014-2019 Highlander body-side hatch seal Fitment/availability: Live direct catalog offer showing Add to Ca…
Toyota 76872-0E030 genuine rear-spoiler protector No. 1
renew the spoiler attachment protector only when the water test identifies that path Fitment/availability: VIN-confirmed 2014-2019 Highlander spoiler branch; use the exact spoiler diagram because additional protectors can be required Fit…
Fourth-generation (XU70) Highlanders with the panoramic/twin-panel moonroof are widely reported to develop a rattle or creaking noise over bumps and on angled driveway approaches, caused by the glass and seal rubbing against the folded sheet-metal roof edge. A separate but related complaint is water intrusion at the roof rail / moonroof drains, staining the headliner and A-pillar trim when the drains clog or seals fail. Both issues are persistent and often recur after initial dealer attempts.
Common Symptoms
Creak or rattle from roof area over bumps and driveway inclines
Wind noise around the moonroof at speed
Water dripping from headliner or A-pillar after rain/car wash
Stained or wet headliner near roof rail
Damp carpet from clogged moonroof drains
How to Fix
For the rattle, dealers apply felt/foam tape or adjust the glass-to-frame clearance and seal; persistent cases may need seal or glass reseating. For leaks, clear the four moonroof drain tubes and reseat or replace the moonroof seal/drain grommets; verify drains route water out at the rocker/door areas. Periodic drain cleaning prevents recurrence.
What you need to fix it
Only diagnosis- and fitment-reviewed repair parts are linked here.
Toyota 63251-0E100 genuine panoramic sliding-roof weatherstrip
replace only after inspection or water testing proves perimeter weatherstrip damage or leakage Fitment/availability: VIN-confirmed 2020-2024 Highlander equipped with the panoramic moonroof Fitment/availability: Live direct product page s…
Fourth-generation Highlander owners widely report excessive wind noise that intensifies at highway speed (typically 40 mph and up) — a whistle near the windshield/upper A-pillar or sunroof area and noise off the exterior mirror housings — which Toyota has acknowledged as a poor-seal issue. Separately, the panoramic/standard moonroof rattles and creaks over bumps and on inclines, traced to the glass/actuators in the roof rail channel. These are top-searched NVH complaints for the current generation despite TSB-level seal corrections.
Common Symptoms
Whistling wind noise at 40+ mph
Rattle/creak from the sunroof over bumps
Noise off the side mirrors at speed
Noise that changes when pressing up on the sunroof glass
How to Fix
For wind noise, have the A-pillar/windshield weatherstrip and mirror seals inspected and the applicable TSB seal correction applied; owner-level fixes include adding window/foam insulation under the hood weatherstrip and reseating the A-pillar trim. For the sunroof rattle, applying 3M clear silicone paste to the moonroof rail channel and the black glass actuators is a common, effective owner fix; a dealer may reseat or shim the glass. Costs are usually low ($0-$200) and largely labor/diagnostic; under warranty the seal TSB should be free.
What you need to fix it
Only diagnosis- and fitment-reviewed repair parts are linked here.
Toyota 53115-0E010 genuine revised radiator grille bracket
Toyota bulletin repair for the specifically diagnosed front grille-bracket whistle—not a sunroof, mirror or A-pillar repair Fitment/availability: Only a VIN-confirmed non-XSE 2020-2022 Highlander or Highlander Hybrid that reproduces the …
Second-generation Highlanders with the 2GR-FE V6 commonly set a check engine light for an upstream air/fuel ratio sensor whose signal sticks on the lean side of its range. The characteristic Toyota pattern is a downstream oxygen sensor circuit-high code (P0138 bank 1 or P0158 bank 2) appearing together with, or instead of, the A/F sensor code (P2195 bank 1, P2197 bank 2) — the ECM flags the rear sensor because the front sensor's slow response drives the fuel trim, so shops that replace the downstream O2 sensor first fix nothing. Toyota published a service bulletin covering 2008-2010 Highlander for exactly this combination, attributing it to incorrect air/fuel ratio sensor response. Symptoms are mild — a light, slightly worse fuel economy, occasional rough idle — but the car will fail emissions testing.
Common Symptoms
Check engine light on
Slightly reduced fuel economy
Occasional rough or hunting idle
Fails state emissions test
Downstream O2 code returns after replacing the rear sensor
How to Fix
Check the A/F sensor harness for opens, shorts and chafing first; if the wiring is sound, replace the affected bank's upstream air/fuel ratio sensor. Use a genuine Denso/Toyota sensor — aftermarket A/F sensors are a repeat-failure source on this engine. Anti-seize sparingly on the threads only, never on the sensor tip. Bank 1 is the front (radiator-side) bank on the transverse 2GR-FE; bank 2 is the firewall side and is the harder of the two to reach. This is not covered by any recall.
A very common Highlander check-engine complaint is P0420 (Catalyst Efficiency Below Threshold, Bank 1) and its Bank 2 twin P0430. The downstream oxygen sensor readings track the upstream sensor too closely, indicating the catalytic converter is no longer scrubbing exhaust efficiently. Root causes are an aged/failed converter, a lazy air-fuel or downstream O2 sensor, or an exhaust leak upstream. It fails emissions inspections and is a frequent search/complaint across model years.
Common Symptoms
Check engine light with P0420 and/or P0430
Reduced fuel economy
Sulfur/rotten-egg exhaust smell
Emissions test failure
Occasional mild hesitation
How to Fix
Diagnose before replacing: verify no exhaust leaks, check for oil/coolant consumption that poisons the cat, and scope O2/AF sensor switching. If a sensor is lazy, replace it (use Denso/OEM). If the monitor confirms low catalyst efficiency, replace the affected catalytic converter (California/CARB vehicles require a CARB-compliant unit). Clear codes and re-run readiness monitors.
The evaporative-emissions system commonly sets P0441 (incorrect purge flow) and P0455/P0446 (large leak / vent malfunction). The vapor canister purge valve (VSV) sticks open or closed, or the charcoal canister breaks down internally and sheds pellets that clog the system. A classic symptom is the gas-pump nozzle repeatedly clicking off before the tank is full, plus a fuel-vapor smell. A loose/failed gas cap or cracked filler-neck boot can also set the codes.
Common Symptoms
Check engine light P0441 / P0455 / P0446
Gas pump clicks off repeatedly while fueling
Fuel/vapor odor
Slight rough idle after refueling
Failed emissions/EVAP test
How to Fix
Start with the cheapest causes: reseat/replace the fuel cap and inspect the filler-neck boot. Test the purge VSV and vent valve; replace the sticking solenoid (e.g., Genuine purge valve 25860-0P090 on 2008–2011 3.5L applications — verify by VIN as part numbers were superseded). If charcoal is contaminating the lines, replace the vapor canister and clear the pellets from the purge/vent circuit.
What you need to fix it
Only diagnosis- and fitment-reviewed repair parts are linked here.
Toyota 90910-12204 genuine duty vacuum switching valve
replacement purge/VSV only after testing proves this engine-specific valve sticks, leaks or fails to actuate Fitment/availability: VIN-confirmed 2008-2013 Highlander gas 3.5L 2GR-FE purge/VSV branch whose Toyota diagram calls for 90910-1…
Toyota 90910-12276 genuine duty vacuum switching valve
replacement purge/VSV after electrical, sealing and flow testing identifies this exact valve Fitment/availability: VIN-confirmed Highlander gas branch whose current vacuum-piping diagram calls for 90910-12276 or 90910-TC001; the reviewed…
Toyota 77740-0E020 genuine charcoal canister assembly
replacement canister only after smoke/flow testing or visible charcoal contamination proves the canister is leaking, restricted or breaking down Fitment/availability: VIN-confirmed 2008-2013 Highlander gas ASU40/GSU40/GSU45 branch; repla…
lowest-cost replacement only when inspection or cap testing confirms a damaged seal, ratchet or sealing surface Fitment/availability: VIN-confirmed 2008-2013 Highlander branch using 77300-06040; verify emissions package and current super…
replacement cap only when the later-generation cap or seal is proven unable to hold the EVAP test pressure Fitment/availability: VIN-confirmed 2014-2017 Highlander gas ASU50/GSU50/GSU55 branch; Hybrid and later vehicles have separate cat…
Highlanders equipped with rear air conditioning route refrigerant lines along the underbody, up the passenger side, to a rear evaporator and expansion valve behind the trim. Those long runs, their crimped hose-to-aluminium-line joints, and the rear evaporator core itself are a well-documented leak point on the second-generation cars — the joint where the black flexible hose meets the aluminium hard line behind the rear passenger wheel shows up repeatedly under UV dye. Because front and rear circuits share one charge, condenser and compressor, the rear vents lose cooling first as the charge falls, then the front follows; owners who top up refrigerant see cooling return for a season and then lose it again. This is distinct from the front condenser rock-strike failure: the leak is behind or beneath the vehicle, and a rock strike is not the cause.
Common Symptoms
Rear A/C vents blow warm while front is still cool
Both front and rear lose cooling over a season
Oily residue or dye trace behind the rear passenger wheel
A/C compressor short-cycles or will not engage on low charge
Cooling returns temporarily after a recharge, then fades
How to Fix
Do not just recharge. Add UV dye and pressure-test, then inspect the passenger-side underbody lines (especially the hose-to-hard-line crimp behind the rear passenger wheel), the rear evaporator core and the rear expansion valve. If the rear evaporator is the leak, the rear trim and headliner-side panel come out to reach it; if the line is the leak, the underbody line assembly is replaced. Evacuate, replace the receiver/drier, and recharge to spec by weight. If refrigerant is fine but only the rear is warm, the rear expansion valve is the prime suspect rather than a leak.
The front-mounted A/C condenser on the Highlander is built with thin fins/tubes that owners say cannot survive a stray rock, so it develops small refrigerant leaks and loses cooling — and because the condenser sits low and forward, it gets struck more often than on many vehicles. CarComplaints documents A/C condenser damage on the 2020 Highlander, and forum owners report the same on earlier third-gen cars. Repairs almost never hold; the condenser must be replaced.
Common Symptoms
A/C blows warm or cools weakly
Visible damage/bent fins on the front condenser
Refrigerant leak (oily residue) at the condenser
A/C works then loses cooling again after a recharge
How to Fix
Diagnose with a leak/dye test and pressure check. Replace the condenser (sealant/weld repairs rarely hold and can contaminate the system), then evacuate and recharge with the correct refrigerant and oil charge. The condenser itself is usually ~$100-$250; full replacement with evacuate/recharge commonly runs $600-$1,100 at a dealer (roughly a 2-hour job plus refrigerant). A protective grille/condenser screen can reduce repeat rock damage.
What you need to fix it
Only diagnosis- and fitment-reviewed repair parts are linked here.
Toyota 88460-0E070 genuine A/C condenser assembly
replacement condenser after a leak is positively localized to the gas-model condenser Fitment/availability: VIN-confirmed 2014-2019 Highlander gas/non-hybrid branch; seller lists 2.7L and 3.5L fitment, but confirm exact model code before…
replacement condenser after a leak is positively localized to the hybrid-model condenser Fitment/availability: VIN-confirmed 2014-2019 Highlander Hybrid branch only; do not interchange with 88460-0E070 gas-model plumbing Fitment/availabi…
Toyota 884A0-0E010 genuine A/C condenser assembly
early-production XU70 condenser replacement after the leak and exact catalog branch are confirmed Fitment/availability: VIN- and production-date-confirmed 2020-2021 Highlander branch whose current Toyota catalog calls for 884A0-0E010; do…
later-production XU70 gas-model condenser replacement after the leak and production-date split are confirmed Fitment/availability: VIN-confirmed late-production 2020-2021 Highlander gas branch, described by dealer catalog as from Decembe…
A widely reported Highlander complaint is a clunk, knock or rattle from the front suspension over bumps and during turns. The most common culprits are worn upper strut mounts (including the bearing, which can also cause a creak when steering), tired struts, control-arm bushings, and worn sway-bar end links. It is a comfort/NVH and eventually a handling concern as components loosen.
Common Symptoms
Clunk/knock over bumps from the front
Creak or click when turning the steering wheel
Rattle from front end on rough roads
Excessive bounce/poor damping
Uneven tire wear
How to Fix
Inspect and isolate the source: check sway-bar end links (a cheap common cause), strut mounts and bearings, control-arm bushings, and ball joints for play. Replace worn end links first when confirmed; replace strut mounts/bearings (ideally with the strut assembly) and bushings as needed, then perform an alignment.
What you need to fix it
Only diagnosis- and fitment-reviewed repair parts are linked here.
Toyota 48609-0E020 genuine front strut mount/support
replacement upper support when inspection proves rubber separation, looseness or mount noise Fitment/availability: VIN-confirmed 2008-2013 Highlander front mount position and build; catalog diagrams use this number for the applicable sid…
Toyota 48609-0E060 genuine front strut mount/support
later-generation upper support when the mount is the localized clunk or steering-noise source Fitment/availability: VIN-confirmed 2014-2018 Highlander front mount position; verify left/right catalog position and required bearing/hardware…
Toyota 48619-42010 genuine front strut mounting bearing
replacement bearing when binding, notchiness or bearing noise is confirmed with the mount apart Fitment/availability: VIN-confirmed 2014-2016 Highlander front strut-bearing branch only; do not extend it to 2008-2013 or 2017-2018 without …
Toyota 43340-49035 genuine front-left lower ball joint
left lower ball-joint replacement only after measured play, torn boot or joint binding/noise is confirmed Fitment/availability: VIN-confirmed 2008-2013 Highlander front driver-side lower ball-joint branch; replaces 43340-49015 Fitment/av…
Toyota 43330-49165 genuine front-right lower ball joint
right lower ball-joint replacement only after measured play, torn boot or joint binding/noise is confirmed Fitment/availability: VIN-confirmed 2008-2013 Highlander front passenger-side lower ball-joint branch; replaces 43330-49125 Fitmen…
Third-generation (XU50) Highlanders develop a loud squeak, squawk or groan from the rear suspension when the body moves over bumps, speed humps, driveways and parking-lot transitions. The noise is worst in cold weather and can be reproduced by bouncing the rear of the vehicle by hand. The cause is the bushing in the rear trailing arm, not the shocks, sway bar links or springs — which is why owners who replace shocks first get no improvement. Toyota acknowledged the condition in Technical Service Bulletin T-SB-0211-17 (revised to cover 2014-2019 Highlander and Highlander Hybrid) and directs the technician to replace the rear trailing arm assemblies. It affects every XU50 model year and is one of the most-discussed complaints in the 3rd-gen owner community.
Common Symptoms
Squeak, squawk or groan from the rear over bumps
Noise much worse in cold weather and on first drive
Noise when loading passengers into the third row
Creak when the body rocks in a parking lot or driveway
Noise unchanged after replacing rear shocks
How to Fix
Under warranty the TSB remedy applies: dealer confirms the noise and replaces the rear trailing arm assemblies free of charge under the new-vehicle warranty per T-SB-0211-17. Out of warranty, replace both rear trailing arms (or press in new bushings) in pairs and follow with a mandatory four-wheel alignment — skipping the alignment causes rapid inner-edge tire wear. Greasing the bushing is a temporary palliative only; the noise returns.
On XU40 Highlanders the second-row seat uses a latch, cable and linkage assembly to fold the seatback and auto-slide the seat forward for third-row access. The plastic cable retainer in the latch mechanism cracks and lets the release cable jump out of position, and the cables themselves stretch, fray or disconnect. Once that happens the seatback will not fold, will not stay folded, or the seat will not auto-slide — leaving the third row effectively unreachable in a three-row family vehicle. Owners also report the seat becoming stuck in the folded or walk-in position, requiring a tool reached under the seat to trip the latch. The third-row 60/40 seatback release suffers from the same cable-and-latch design. This is a mechanical wear-and-plastic-fatigue issue with no recall behind it; note it is a different failure from the 2021-2024 second-row seat-back locking recall on the XU70.
Common Symptoms
Second-row seatback will not fold forward
Seat does not auto-slide for third-row access
Release strap pulls with no resistance or does not return
Seat stuck in the folded or walk-in position
Third-row 60/40 seatback will not release
How to Fix
Diagnose which end has failed: inspect the top latch and side lever for engagement, and check both release cables for tension, fraying and disconnection at the cracked plastic retainer. A broken retainer or stretched cable is repaired by replacing the seatback release cable and latch assembly rather than the whole seat; salvage-yard latch assemblies are a common cost saver. If the seat is jammed in the stowed or folded position, the latch can usually be tripped manually from underneath with a flat bar to free it before disassembly. Avoid yanking the release strap hard, and be careful when fitting aftermarket seat covers, which owners report over-tensioning and snapping the cable.
The sun visors slowly rotate/droop downward and no longer hold position, obstructing the driver's view. The internal pivot friction mechanism wears out and cannot support the visor's weight. Toyota acknowledged the defect with a Warranty Enhancement / Customer Support Program (code ZF1) for 2010–2013 Highlanders, covering visor assembly/bracket replacement for 7 years from first use with no mileage cap. The same droopy-visor failure mode recurs on later generations as a common (non-covered) complaint.
Common Symptoms
Sun visor slowly droops down on its own
Visor won't stay in the up position
Loose/floppy visor pivot
Visor blocks forward view while driving
How to Fix
Replace the sun visor assembly (the pivot is sealed and not serviceable). Eligible 2010–2013 vehicles were replaced free under program ZF1; otherwise it is an inexpensive ~15-minute DIY with a trim pry tool and Phillips screwdriver. Match the correct color/trim part by VIN.
What you need to fix it
Only diagnosis- and fitment-reviewed repair parts are linked here.
Toyota 74320-48500-B0 genuine left sun visor assembly, gray
complete driver-side visor replacement when the sealed hinge or detent no longer holds Fitment/availability: VIN- and option-confirmed 2010-2013 Highlander driver side in the matching gray interior/configuration Fitment/availability: Liv…
Toyota 74320-48500-E0 genuine left sun visor assembly, sand beige
sand-beige driver-side branch of the complete sealed visor repair Fitment/availability: VIN- and option-confirmed 2010-2013 Highlander driver side in the matching sand-beige interior/configuration Fitment/availability: Live direct produc…
Toyota 74310-48520-B0 genuine right sun visor assembly, gray
complete passenger-side visor replacement when its sealed hinge fails Fitment/availability: VIN- and option-confirmed 2010-2013 Highlander passenger side in the matching gray interior/configuration Fitment/availability: Live direct produ…
Toyota 74310-48520-E0 genuine right sun visor assembly, sand beige
sand-beige passenger-side branch of the complete sealed visor repair Fitment/availability: VIN- and option-confirmed 2010-2013 Highlander passenger side in the matching sand-beige interior/configuration Fitment/availability: Live direct …
AWD Highlanders (and platform-mate Sienna/Venza) develop an abnormal whine, hum, roar or growl from the rear that grows louder with vehicle speed. The source is typically the electromagnetic AWD coupling assembly ahead of the rear differential and/or its two supporting ball bearings, which wear and become noisy. Toyota issued a TSB describing the noise and the coupling/bearing repair. Running mismatched tire sizes or flat-towing accelerates the damage and can void warranty coverage.
Common Symptoms
Whine/hum/growl from rear that increases with speed
Roaring noise steady with vehicle (not engine) speed
Vibration from rear at highway speed
Noise louder on deceleration or coasting
How to Fix
Diagnose whether the noise is the bearings or the coupling. Repair options are replacing the two radial ball bearings, or replacing the bolt-on electromagnetic coupling assembly. Use matched tires (same size/wear) on all four corners to prevent recurrence. Confirm the rear differential fluid is not overdue.
What you need to fix it
Only diagnosis- and fitment-reviewed repair parts are linked here.
Toyota 41303-48030 genuine electromagnetic AWD coupling assembly
complete coupling replacement only after the noise is localized to the electromagnetic coupling rather than tires, hubs, shaft or differential gears Fitment/availability: VIN-confirmed 2015-2019 Highlander mechanical-AWD branch only; sel…
Toyota 08885-02506 genuine LT 75W-85 gear oil, 1 quart
correct-spec service fluid when the rear differential is due, contaminated or opened—not a bearing-noise cure Fitment/availability: Use only where the VIN-specific Highlander repair manual specifies Toyota LT 75W-85/API GL-5 or the curre…
2GR-FE Highlanders produce a low-frequency drone or boom inside the cabin whenever the engine passes through roughly 1,500-2,000 rpm under load, independent of road speed — most noticeable in light-throttle cruise and on gentle hills where the transmission holds a tall gear. It is exhaust resonance transmitted structurally, not through the air: Toyota bolted an exhaust support bracket rigidly to the engine/transmission with no flex joint at that point, so pipe resonance couples directly into the body. Owners on ToyotaNation have documented it across hundreds of pages, and report the cabin goes Lexus-quiet with the bracket removed. Some dealers have fitted a redesigned exhaust manifold (17140-0P250) that Toyota revised in response to complaints. Toyota never issued a formal TSB, so dealers frequently tell owners it is 'normal' — which is why it belongs on a buyer's checklist rather than a warranty claim.
Common Symptoms
Low-frequency drone or boom in the cabin at 1,500-2,000 rpm
Noise present regardless of road speed, tied to engine rpm
Worse under light load on gentle inclines
Vibration felt through the floor and seats
Dealer says the noise is normal
How to Fix
There is no recall and no official TSB. The two remedies owners report working: (1) have the dealer fit the revised exhaust manifold, part 17140-0P250, which Toyota redesigned after complaints — worth pursuing while in powertrain warranty; (2) decouple the rigid exhaust support bracket that bolts to the transmission case, replacing it with a rubber-isolated hanger so the pipe resonance no longer transmits into the body. Adding a resonator to the mid-pipe is a third route. Check exhaust hangers and heat-shield contact before spending money, since worn hangers make it dramatically worse.
Toyota Motor Engineering & Manufacturing (Toyota) is recalling certain 2023-2024 Toyota Venza, 2023-2025 RAV4 Prime, RAV4, Highlander, GR Corolla, Crown, 2024-2025 Lexus TX, LS, Toyota Tacoma, Grand Highlander, and 2025 Lexus RX, Toyota Crown Signia, Camry, RAV 4 Plug-in Hybrid (PHEV), and 4 Runner vehicles. Due to an error in the instrument panel software at vehicle startup, the instrument panel may fail to display vehicle speed, brake system, and tire pressure warning lights.
Campaign #25V59500011/09/2025
BACK OVER PREVENTION:DISPLAY FUNCTION
Toyota Motor Engineering & Manufacturing (Toyota) is recalling certain 2022-2026 Toyota, Lexus, and Subaru Solterra vehicles equipped with a Panoramic View Monitor (PVM) system. Please see the recall report for a complete list of models. A software error may cause the rearview camera to freeze or display a blank screen when the vehicle is in reverse. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard (FMVSS) number 111, "Rear Visibility."
Repair costs for known Toyota Highlander issues range from $0 to $12,000, depending on the specific problem and whether you choose DIY or professional repair. The most critical issue, 2GR-FE V6 Excessive Oil Consumption, typically costs $0-$4,000 to repair. Au7o provides step-by-step DIY maintenance guides that can help reduce repair costs.
What year Toyota Highlander is the most reliable?
Reliability varies across model years of the Toyota Highlander. Based on documented issues, problems are most commonly reported in earlier model years. Au7o recommends checking the specific known issues for your target year before purchasing, and having a pre-purchase inspection performed by a qualified mechanic. Our known issues database covers the 2001-2025 Toyota Highlander with 51 documented issues documented across 4,230+ owner reports.
What is the 2008-2013 Toyota Highlander 2GR-FE V6 Excessive Oil Consumption?
The 3.5L 2GR-FE V6 in 2nd-gen Highlanders consumes oil excessively, often 1 quart per 1,000-2,000 miles. The root cause is piston ring design allowing oil past the rings into the combustion chamber. Repairs typically run $0-$4,000. Severity: high.
What is the 2006-2013 Toyota Highlander Hybrid Battery Pack Degradation and Failure?
Highlander Hybrid NiMH battery packs degrade over time, with individual cells failing after 8-12 years or 150,000+ miles. Failed cells cause reduced fuel economy, loss of hybrid assist, and eventual inability to start the vehicle. Repairs typically run $1,500-$5,500. Severity: high.
What is the 2020-2024 Toyota Highlander UA80 8-Speed Transmission Whine/Grind — Front Carrier Pinion Shaft Failure?
The UA80E/UA80F 8-speed automatic in V6 Highlanders can develop a whine or grind noise traced to defective front carrier assembly pinion shafts/bearings. As the bearings delaminate they shed metal debris through the fluid, which can progressively damage the torque converter and t… Repairs typically run $0-$12,000. Severity: high.
What is the 2017-2019 Toyota Highlander Denso Low-Pressure Fuel Pump Failure Causing Engine Stalling (Recall 20V-012)?
Certain Highlanders are part of Toyota's large Denso low-pressure fuel pump recall (NHTSA 20V-012). The pump's resin impeller can absorb fuel, swell, and crack, causing the pump to seize. This leads to rough running, hard starting, and engine stalling — potentially at speed and w… Repairs typically run $0-$800. Severity: high.
What is the 2001-2007 Toyota Highlander 2.4L 2AZ-FE Head Gasket and Head Bolt Thread Failure?
The 2001-2007 Highlander with the 2.4L 2AZ-FE 4-cylinder engine suffers from a design flaw where the aluminum head bolt threads strip out of the engine block. The plastic intake manifold traps heat against the block, causing thermal fatigue of the aluminum threads. This leads to… Repairs typically run $2,500-$5,000. Severity: high.
What is the 2008-2013 Toyota Highlander 2GR-FE V6 Oil Leak (Timing Cover and Oil Cooler Line)?
The 3.5L 2GR-FE V6 in the 2008-2013 Highlander develops two significant oil leak patterns. The timing cover sealant fails over time, causing a slow but persistent oil leak from the front of the engine that worsens progressively. More critically, the rubber oil cooler hose can rup… Repairs typically run $300-$4,000. Severity: high.
What is the 2023-2025 Toyota Highlander Cluster Fails to Show Speedometer and Brake/Tire Pressure Warnings After Start (Recall 25V595000)?
2023-2025 Highlanders are among the vehicles named in NHTSA recall 25V595000. Toyota reports an error in the instrument panel software that occurs at vehicle startup; when it happens, the instrument panel may fail to display vehicle speed along with the brake system and tire pres… Severity: high.
What is the 2015 Toyota Highlander Electric Power Steering ECU Damaged in Manufacture — Sudden Loss of Steering Assist (Recall 15V144000)?
A component inside the electric power steering ECU on certain 2015 Highlander and Highlander Hybrid vehicles was damaged during the manufacturing process. The damage progresses over time and can end in outright failure of the EPS system, meaning the driver loses power assist with… Repairs typically run $0-$1,800. Severity: high.
What is the 2021-2024 Toyota Highlander Second-Row Seat Back May Fail to Lock (Recall 26V-128)?
Toyota recalled approximately 550,007 model-year 2021-2024 Highlander and Highlander Hybrid SUVs (NHTSA 26V-128) because the second-row seat-back recliner teeth may not fully engage when the seat back is adjusted, due to a supplier design change to the recliner guide/ratchet comb… Repairs typically run $0-$0. Severity: high.
What is the 2007-2008 Toyota Highlander 2GR-FE VVT-i Oil Supply Hose Rupture — Sudden Oil Loss (Service Campaign LSC 90K)?
On 2GR-FE 3.5L V6 engines (built up through roughly April 2008), the rubber center section of the oil supply hose that feeds the VVT-i actuator degrades from exposure to corrosive PCV gases. A pinhole forms and expands, then the hose bursts, dumping engine oil rapidly. Owners rep… Repairs typically run $250-$900. Severity: high.
What is the 2020 Toyota Highlander Incorrect Front Seat Trim Covers Block Seat-Mounted Side Air Bag Deployment (Recall 20V633000)?
Approximately 3,121 model-year 2020 Highlander and Highlander Hybrid vehicles were built with incorrect trim covers on one or both front seats. The seat-mounted side air bag deploys through a tear seam in the seat trim; a cover without the correct seam construction can suffocate… Repairs typically run $0-$0. Severity: high.
What is the 2024-2025 Toyota Highlander Third-Row Center Seat Belt Roof Anchor Installed at the Wrong Angle (Recall 25V872000)?
On certain 2024-2025 Highlander and Highlander Hybrid vehicles the roof anchor for the third-row center seat belt was installed at an incorrect angle during assembly. A shoulder-belt anchor that sits at the wrong angle can let the webbing load improperly in a crash, so the belt m… Repairs typically run $0-$0. Severity: high.
What is the 2020-2022 Toyota Highlander Occupant Classification System (OCS) Sensor Short Circuit — Front Passenger Air Bag Will Not Deploy (Recall 23V865000)?
The front passenger seat on 2020-2022 Highlander and Highlander Hybrid vehicles carries an Occupant Classification System sensor mat that weighs the occupant and tells the air bag control module whether — and how hard — to fire the passenger air bag. Improperly manufactured senso… Repairs typically run $0-$1,300. Severity: high.
What is the 2006-2010 Toyota Highlander Hybrid Inverter Intelligent Power Module (IPM) Transistor Solder Failure — Hybrid System Shutdown/Stall (Recall 13V396000)?
On the first- and second-generation Highlander Hybrid (2GR-FXE / 3MZ-FE hybrid), the Intelligent Power Module inside the hybrid inverter assembly carries control-board transistors whose operating temperature can exceed what the solder beneath them tolerates. The solder degrades,… Repairs typically run $0-$4,500. Severity: high.
What is the 2023 Toyota Highlander Steering Column Spiral Cable Weld Separation — Driver's Air Bag Deactivated (Recalls 23V480000 and 25V040000)?
An electrical connection inside the steering-column spiral cable (clock spring) assembly on certain 2023 Highlander and Highlander Hybrid vehicles was insufficiently welded at the supplier. Over time and with normal steering-wheel rotation the connection can separate, breaking th… Repairs typically run $0-$900. Severity: high.
What is the 2006-2019 Toyota Highlander Hybrid Inverter Coolant Pump Failure (Inverter Overheat) — P0A05 / P0A93?
The Highlander Hybrid uses a dedicated electric water pump to circulate coolant through the power inverter/converter, which runs separately from the engine cooling system. The electric pump wears out and stops circulating coolant, allowing the inverter and hybrid electronics to o… Repairs typically run $700-$1,100. Severity: high.
What is the 2006-2013 Toyota Highlander Hybrid Brake Booster / ABS Actuator Assembly Failure (Accumulator Leak) — C1391?
The regenerative-braking brake actuator (the integrated ABS/booster/accumulator pump module) is a known weak spot on the Highlander Hybrid. The accumulator develops an internal leak and the pump runs constantly, triggering a loud, repetitive whirring/buzzing and warning lights; i… Repairs typically run $1,600-$3,500. Severity: high.
What is the 2001-2013 Toyota Highlander Radiator Internal Transmission-Cooler Failure — ATF/Coolant Cross-Contamination ("Strawberry Milkshake")?
Automatic-transmission Highlanders route ATF through a cooler integrated into the main radiator end tank. When the internal separator corrodes/cracks, engine coolant and transmission fluid mix, producing a pink 'strawberry milkshake' emulsion. Coolant in the ATF destroys the clut… Repairs typically run $400-$4,500. Severity: high.
What is the 2001-2007 Toyota Highlander V6 Engine Oil Sludge / Gelling (1MZ-FE / 3MZ-FE) — Oil Pump Pickup Starvation?
The early Highlander 3.0L 1MZ-FE (and successor 3.3L 3MZ-FE) V6 is prone to engine oil sludge/gelling. Blow-by gases and moisture that fail to burn off (aggravated by short-trip driving, extended oil intervals and a PCV valve that clogs) turn the oil to a gel that coats the valve… Repairs typically run $500-$6,000. Severity: high.
What is the 2009-2013 Toyota Highlander 1AR-FE 2.7L Four-Cylinder Excessive Oil Consumption (Low-Tension Ring / Carbon Buildup)?
The four-cylinder 1AR-FE 2.7L offered on the base second-gen Highlander is notorious for burning oil, especially when owners follow Toyota's 10,000-mile oil-change interval. The engine uses low-tension piston rings for fuel economy, and carbon buildup clogs the oil-control ring g… Repairs typically run $200-$3,500. Severity: high.
