2004 Toyota Highlander Problems: 3 Known Issues
2004 model year · NHTSA recalls, manufacturer TSBs, and owner forum reports · Updated October 2026
According to Au7o's research across NHTSA recalls, manufacturer TSBs, and owner forum reports, the 2004 Toyota Highlander has 3 documented known issues, with 2 rated critical. The most serious are 2.4L 2AZ-FE Head Gasket and Head Bolt Thread Failure ($2,500-$5,000 repair) and Radiator Internal Transmission-Cooler Failure — ATF/Coolant Cross-Contamination ("Strawberry Milkshake") ($400-$4,500 repair). Across all issues with published estimates, repair costs range from $200 to $5,000. DIY maintenance guides at au7o.io.
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All 3 Known Issues
NHTSA Recalls11 recalls
ELECTRICAL SYSTEM
Fujian Wanda Automobile Glass Industry (Wanda) is recalling certain aftermarket Replacement Windshields sold for use in 2014-2018 Toyota Highlander vehicles. The windshields have an attached wire harness that water may leak into, possibly causing damage to the vehicle's Engine Control Module (ECM).
ELECTRICAL SYSTEM:WIRING
Toyota Motor Engineering & Manufacturing (Toyota) is recalling certain model year 2016 Highlander vehicles manufactured May 26, 2016, to September 16, 2016. The brake fluid level sensor may not be connected to the wire harness, preventing the sensor from detecting the brake fluid level. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard (FMVSS) No. 135, "Light Vehicle Brake Systems."
EQUIPMENT:OTHER:LABELS
Southeast Toyota Distributors, LLC (SET) is recalling certain model year 2016 Toyota Camry and Highlander, 2015-2016 Toyota Tundra, Scion FR-S, and tC vehicles. The Load Carrying Capacity Modification Label may not reflect the correct added weight of the installed accessories. As a result, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard number 110, "Tire Selection and Rims for Passenger Cars."
AIR BAGS:FRONTAL:SENSOR/CONTROL MODULE-INACTIVE
Southeast Toyota Distributors, LLC (SET) is recalling certain models interspersed through model years 2009 through 2013 as follows: model year 2009-2012 Tacoma, 4Runner, Camry, Camry Hybrid, Prius, and RAV4; model year 2009-2010 Avalon, FJ Cruiser, and Highlander Hybrid; model year 2010-2013 model year Corolla, Sienna and Tundra; model year 2009-2013 Highlander and Venza; model year 2012 Prius V; and model year 2010-2012 Sequoia. During modification by SET to include accessories such as leather seat covers, seat heaters or headrest DVD systems, these vehicles may not have had the passenger seat occupant sensing system calibration tested. Without passing the calibration test, the occupant sensing system may not operate as designed.
EQUIPMENT:OTHER:LABELS
Southeast Toyota is recalling certain model year 2008 and 2010-2013 Toyota Tundra, 2010-2012 Rav4, 2012 Toyota Sequoia, 2010-2011 Toyota Corolla, 2010-2011 Toyota Camry and Camry Hybrid, 2010-2013 Toyota Highlander and Highlander Hybrid, 2010-2013 Toyota FJ Cruiser, 2011 Toyota Land Cruiser, 2010-2013 Toyota Venza, 2010-2011 Toyota 4Runner, 2010-2013 Toyota Tacoma, 2011-2012 Toyota Sienna, 2012 Toyota Prius, 2013 Scion FR-S, 2011 Scion XD, 2011 Scion XB, and 2012 Scion TC vehicles. These vehicles were sold with labels that were outside the allowable one percent of accuracy of actual weight added. Thus, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard (FMVSS) Number 110, "Tire Selection and Rims."
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Frequently Asked Questions
What are the most common Toyota Highlander problems?
According to Au7o's research across NHTSA recalls, manufacturer TSBs, and owner forum reports, the 2004 Toyota Highlander has 3 documented issues. The most frequently reported are: 2.4L 2AZ-FE Head Gasket and Head Bolt Thread Failure, Radiator Internal Transmission-Cooler Failure — ATF/Coolant Cross-Contamination ("Strawberry Milkshake"), Catalytic Converter Efficiency Failure — P0420 / P0430 Check Engine Light. Of these, 2 are rated critical and should be addressed promptly.
Is the Toyota Highlander reliable?
The 2004 Toyota Highlander has 3 known issues compiled from NHTSA recalls, manufacturer TSBs, and owner forum reports. 2 issues are rated critical: 2.4L 2AZ-FE Head Gasket and Head Bolt Thread Failure and Radiator Internal Transmission-Cooler Failure — ATF/Coolant Cross-Contamination ("Strawberry Milkshake"). 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?
Repair costs for known Toyota Highlander issues range from $200 to $5,000, depending on the specific problem and whether you choose DIY or professional repair. The most critical issue, 2.4L 2AZ-FE Head Gasket and Head Bolt Thread Failure, typically costs $2,500-$5,000 to repair. Au7o provides step-by-step DIY maintenance guides that can help reduce repair costs.
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 head bolts pull out of the block threads, letting the head gasket lose clamping force. This leads to head gasket fail… Repairs typically run $2,500-$5,000. 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 2001-2016 Toyota Highlander Catalytic Converter Efficiency Failure — P0420 / P0430 Check Engine Light?
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 efficie… Repairs typically run $200-$2,500. Severity: medium.
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.