2024 Toyota Grand Highlander

The Office of Defects Investigation (ODI) received a Petition dated July 20, 2026. The Petition requests an investigation of road debris / rocks damaging the heat exchangers in model year (MY) 2024-2026 Toyota Grand Highlander vehicles. The Petition contends that the Grand Highlander’s front-end grill has large, open apertures and no protective screen between the grill and the vehicle’s heat exchangers. The Petition further alleges that as a result, during normal driving, the damage to heat exchangers results in coolant leakage and sudden loss of propulsion. The Petitioner cites thirteen (13) complaints received by ODI alleging this failure, which, when added to the petitioner’s own complaint, bring the total under consideration at this time to fourteen (14). ODI will evaluate these complaints to determine if they are related to the failure cited in the Petition and conduct a technical review under 49 CFR Part 552. This Defect Petition is being opened to evaluate whether to grant or deny the petition. The petition can be reviewed at NHTSA.gov under ODI number 11754975.

Rock/ road debris flew in grill (because of wide gaps) and broke my AC condenser

NHTSA ID

11776315

Incident

Nov 2, 2026

My transmission is failing . I started hearing a jet take off or whinning noise from the hood. Because of multiple other stories I read I assumed transmission. Took to dealer in September. They confirmed transmission is failing. The part was on a national back order . The issue caused my car to stutter during take offs . Which could caused me an accident . Also in reverse it would not stop rolling backwards after shifting to drive

NHTSA ID

11776314

Incident

Sep 18, 2026

While driving on highway with wet roads, the steering suddenly seemed to pull to the right causing the vehicle to lose control and spin finally hitting the side barrier. I then noticed that the steering wheel was no longer aligned with the vehicle (photo attached). A few minutes prior I had an issue with the main console/radio unit and had to reboot as no sound was working. This leaves me to believe there was some type of electrical malfunction with the vehicle.

NHTSA ID

11774695

Incident

Oct 30, 2026

The front grill has enlarged holes and a rock was able to penetrate the grill and hit the condenser. It broke the condenser causing a very expensive repair. I made a comprehensive claim with my insurance and they agreed that was the cause of the damage. The grill does not provide sufficient protection for the parts inside. I had no warning lamps go off, the Air conditioner simply stopped working a few days later.

NHTSA ID

11774418

Incident

Sep 6, 2026

Transmission Whining Noise Detected, Automatic Shifting Difficulties, Reduced Power & Acceleration Concerns. Dealer inspected and confirmed transmission failure. Required Dealer replacement under power train warranty. Defect known to exist in Toyota 6 speed Automatic U80A transmissions. Transmission is known to be defective and unreliable, potentially causing catostrophic injury to persons and property with use and operation.

NHTSA ID

11773426

Incident

Oct 19, 2026

On XXX, at about 2:00 PM we were driving south on I95 somewhere in [XXX] when we heard a very loud noise. Thinking it was a rock hitting the windshield we looked but could see no cracks or chips so we kept driving on our trip to [XXX]. The next day it was windy and we thought it was unusually noisy inside the vehicle but we just thought it was the wind. After driving around in [XXX] we said it was unusually noisy inside so I said I would stand on the door sill to look at the roof and that’s when I saw the hole in the sunroof. That night, Sunday, XXX, I called our insurance company to report the damage. They said that an adjuster would contact us on Monday. Meanwhile I started to “Google” issues with sunroofs and there I found out about imploding glass sunroofs. On Monday, XXX, I went to the Toyota service in [XXX].and had them look at the damaged sunroof. The service advisor mentioned he had never seen this damage. He said they could replace it but would have ordered parts which could take a couple days. I said to go ahead as we were only here until Saturday. That day, Monday XXX I called the insurance company to update them. I also stopped at the Toyota dealer to talk with them. I mentioned the “Google” reports about sunroof issues. The advisor said there were no recalls or anything from Toyota on this. He did say that an insurance adjuster had contacted him and said they were very busy but would try to get there to look at the vehicle on Tuesday. We are thankful we did not have the sunroof cover open as we would have had glass all over inside the vehicle. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11772629

Incident

Oct 17, 2026

Incident occurred on XXX at 9:46AM PST, [XXX]. When applying brakes normally to come to a gradual stop behind another vehicle stopped at a stop sign on a slight decline, PCS collision warning lights enabled and vehicle lurched forward while my foot was on brake. This is not to be confused with automatic braking behavior as front collision warning lights in driver information center flashed red. Rather, vehicle lurched forward as if accelerating once within feet of vehicle in front. Then, vehicle rocked front to back multiple times with my foot still on the brake, as if Drive and Reverse was being quickly and intermittently engaged back and forth about 1 second apart. Had my foot not been firmly on the brake, the vehicle felt like it would travel forward and then back (colliding with vehicle in front and in back) without driver inputs.   While car continued to lurch forward and then back, I shifted transmission into Park then back in Drive, and behavior stopped.  There was a loud clunk as the car engaged in Drive.  This has occurred 3 times over the past 2.5 years. What is even more curious, is that this occurred all 3 times at the same stop sign, which is at a slight decline. This leads me to deduce that somehow the angle of decline or other specific condition at this stop sign is somehow contributing or confusing vehicle systems, as bizarre as this sounds. AC was on during at least one preceding event but not during yesterday's event. Others have observed similar events on on-line forums, but I don't know if they have reported this given how infrequently it occurs. Vehicle has 28000+ miles, and I stop at this exact location at least 3 times per week, with behavior observed only 3 times. Statistically, it seems probable that there must be some element (angle of decline?) at this location that somehow confuses vehicle systems, triggering this dangerous unintended acceleration and reversing behavior. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11772339

Incident

Oct 19, 2026

Dear NHTSA Vehicle Safety Team, I am writing to report a serious steering system issue to my 2024 Toyota Grand Highlander Hybrid and to request that NHTSA review this incident for potential safety concerns affecting other owners of the same vehicle model. Vehicle Information - Make and Model: 2024 Toyota Grand Highlander Hybrid - VIN: [XXX] - Mileage at the time of the issue: Approximately 66,000 miles - Component involved: Steering rack/rack-and-pinion assembly Sequence of Events 1. Steering System Failure At 65,000 miles, i started having minor issues with the steering system, but was driving fine. At 85,000 miles i had the vehicle examined at Toyota, (cause steering rack just stuck) informed me the steering rack needed to be replaced, (repair cost 3300$). 2. Vehicle Maintenance History I have maintained my vehicle in a timely manner. at always 5000 miles, during my communication with Toyota's Brand Engagement Center, they acknowledged that my maintenance history was satisfactory. 3. Previous Accident and Service Documentation I contacted Toyota's Brand Engagement Center and requested goodwill assistance with the repair because of the nature of the failure, the vehicle's mileage, and its maintenance history. Toyota ultimately declined to participate in the repair, citing the prior accident. I also requested a written explanation , but denied my request for goodwill assistance, citing the vehicle's involvement in an accident, minor rear end to my rear door and bumper, not my fault. My service documentation dated XXX, (2 months prior the accident) contains a reference to the rack-and-pinion boot and a listed amount of $54.26, this service entry and the eventual steering rack failure to be properly examined. I am not claiming that the accident or the rack-and-pinion boot necessarily caused the failure. I just found out that my model vehicle had a steering wheel recall but 2026 model, maybe has the same issues. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11771226

Incident

Oct 1, 2026

Flash reprogramming allows the Electronic Control Unit (ECU) software to be updated without replacing the ECU. Flash calibration updates for specific vehicle models/ECUs are released as field-fix procedures described in individual Service Bulletins. This bulletin details the Global Techstream+ (GTS+) ECU flash reprogramming procedures and outlines use of the Technical Information System (TIS) and the Calibration Update Wizard+ (CUW+). To ensure the correct ECU software is installed, ECUs will require a Security Signature before the ECU will initialize the flash reprogramming sequence. This bulletin also details the process for acquiring a Security Signature from TIS during the GTS+ ECU flash reprogramming process.

OBSOLETE NOTICE April 17, 2026: This bulletin is now obsolete. Please see T-SB-0028-26

Some 2024 Grand Highlander and Grand Highlander Hybrid vehicles may exhibit a rotational clicking noise from one or both front drive shaft assemblies when accelerating while making turns. This condition may occur without a grease leak present on the front drive shaft assemblies. An updated front drive shaft assembly is available to resolve this condition.

Some 2005 – 2026 Toyota vehicles that have undergone water intrusion may exhibit a condition in which a musty odor is present. Follow the procedures in this bulletin to remediate the odor and address this condition. The purpose of this Service Bulletin is to provide general guidelines and procedures for odor remediation. This Service Bulletin provides a guide on how to prepare and treat the interior of the vehicle for odor remediation. Refer to the applicable model and model year Repair Manual and the EPA (Environmental Protection Agency) website for the most up-to-date safety and precautionary guidelines.

Some 2024 – 2025 model year Grand Highlander and Grand Highlander Hybrid vehicles may exhibit an abnormal fluttering and/or vibration across the rear-center section of the hood. This phenomenon is most notable on darker color vehicles. However, this condition may be noticed on the subject vehicles regardless of the paint color.

The air conditioning dye injection tool kit has been developed to aid in identifying the location of air conditioning refrigerant leaks. The procedures outlined in this Service Bulletin aid in locating, inspecting, and repairing refrigerant leaks.