2024 Toyota Grand Highlander Body & structure Problems

The air conditioning system on my 2024 Grand Highlander failed due to a punctured AC condenser caused by road debris passing through the front grille during normal driving. The front fascia has large open apertures with no protective mesh or screening, leaving the condenser, radiator, and other heat exchangers directly exposed to rocks and debris. The condenser face shows multiple debris strikes, with one impact puncturing the core and causing complete refrigerant loss and AC failure at approximately 62,000 miles. The vehicle worked normally when parked and the AC was completely dead one week later due to the slow refrigerant leak from the puncture. Diagnosis was performed by [XXX] Toyota in [XXX], which confirmed the puncture was caused by road debris. The repair is not covered under warranty or my extended service contract because it is classified as outside damage, leaving owners to pay out of pocket for a design vulnerability. This is the same failure mode described in open ODI Defect Petition No. XXX covering 2024-2026 Grand Highlander vehicles. The same unprotected grille openings expose the engine radiator, meaning the identical debris path can puncture the radiator and cause coolant loss, engine overheating, and sudden loss of propulsion in traffic. The grille design leaves critical cooling components unreasonably vulnerable to everyday road debris. Photos of the punctured condenser and the dealer's written diagnosis are available. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11766783

Incident

Sep 15, 2026

The vehicle’s A/C suddenly began blowing hot air. We took it in for diagnosis. The technician asked if the vehicle had been in an accident, if the front had hit anything, or if we had noticed hitting a rock or other object. We answered no to all questions. The technician stated they have seen this issue numerous times, where road debris passes through the large openings in the factory front grille and damages the A/C condenser. The condenser was found to have localized physical damage of approximately 1 cm in size, consistent with an impact from a rock or other road debris. The impact cracked/punctured the condenser, causing refrigerant to leak from the sealed A/C system and the A/C system to stop functioning. The condenser requires replacement. We researched this issue and found other Toyota owners reporting similar condenser damage from road debris entering through the front grille. We understand that road debris and normal wear can occur, but our concern is that the large factory grille openings allow ordinary roadway debris to directly reach the condenser, with inadequate shielding or protection. A $1,700 repair for a condenser that can be damaged by ordinary road debris entering through the factory grille openings is a significant and potentially recurring expense. Consumers should not reasonably expect to repeatedly incur this level of repair cost because a critical component is inadequately protected from normal roadway conditions, particularly when the vehicle is also covered by an extended warranty that does not cover the repair. This issue also appears relevant to NHTSA Petition DP26006. We ask NHTSA to investigate whether this design leaves the condenser unnecessarily vulnerable to normal roadway debris and whether other vehicles are experiencing the same problem. While the immediate result is loss of A/C, we are concerned about the broader safety implications of critical vehicle components being vulnerable to damage under normal driving conditions.

NHTSA ID

11760369

Incident

Aug 18, 2026

Damage occurred to the front air conditioning system because a rock flew through the open grill area. This punctured the system causing a couple thousand dollar repair, not under warranty. The car was nearly brand new at the time. The grill area is a problem, it's a bad design.

NHTSA ID

11759524

Incident

Oct 1, 2024

The hybrid inverter cooler failed due to an impact with what was described as a rock or road debris shooting through the front grill and striking the inverter cooler so that it leaked coolant and failed. There was no notice of impact, while driving on the highway the hybrid system rapidly went into shut down/safety mode and acceleration and power to the drivetrain of vehicle dramatically reduced. This took a matter of seconds while on the highway without any warning. The problem, cause, effect, and repair was all diagnosed by a Toyota service personnel at a Toyota dealer. It was reported that this is a common issue with the grill design.

NHTSA ID

11759213

Incident

Feb 4, 2026

A rock went through the grill and pierced the AC condenser. The result left us with no AC. Toyota of Grand Rapids charged us $2300 to replace it. The holes in the grill are massive. Toyota of Grand Rapids has a video on file documenting the issue.

NHTSA ID

11758738

Incident

May 7, 2026

It was noted that the drivers door weather strip deteriorated even though the car is less than 3 years old/ 47,000 miles. The dealer and the Toyota customer care said it is likely related to external factors and not covered under warranty. I keep the car in a garage. We have had other cars that are well over 10 years old but do/did not have this problem. This can potentially lead to damage of other components. I see on the internet that other owners of this car have encountered this same issue . There have been 3 safety recalls on this model, related to air bag, instrument panel and rear view camera. These have been fixed. There have been at least 5 Toyota technical service bulletins ( TSBs) published on this model. These were fixed after I brought it up with the dealer/ manufacturer. I was not contacted by the manufacturer proactively. TSB 0017-24 : hesitation felt while accelerating from stop. A software update was performed. TSB 0060-25 : Fuel level logic enhancement. A software update was made. TSB 0028-25 : Shudder sensation at stop. A software update was performed. ​T-SB-0082-24: CV axle issue: it was fixed T-SB-0111-24: vibrating hood.I notice the issue but did not fix it since the fix involves placing a foam under the hood, which may not fix the underlying issue and might cause other issues. I believe these issues are related to the manufacturing oversight and especially more frequent because it is a first year model .

NHTSA ID

11736129

Incident

Mar 1, 2026

Driving at low speeds through my neighborhood, when going on any bumpy road there is a terrible low bass noise. similar to a sub woofer very low bass. it is very annoying and distracting.

NHTSA ID

11627132

Incident

Nov 24, 2024

The hood of the vehicle flexes a lot at highway speeds, and it causes a lot of distraction if the sun is reflected on it. My concern is how much distraction it causes

NHTSA ID

11622092

Incident

Oct 1, 2024

Air bags recall with no resolution. Recall announcement was release in June 19 big safety concern for our family, especially with the cost of the vehicle. We dont trust and won’t feel safe with a airbag replacement

NHTSA ID

11610619

Incident

Jun 19, 2024

I was just recently in an accident where I was T-boned by another driver. My side air bags did not deploy. There is structural damage and my front passenger tire is laid in this this wasn't a light tap on my car.

NHTSA ID

11590893

Incident

May 23, 2024

Subject: NHTSA Complaint - 2024 Grand Highlander Hybrid XLE Rear Windshield Shattering To Whom It May Concern, I am writing to formally file a complaint regarding a concerning incident with my recently purchased 2024 Grand Highlander Hybrid XLE. On [XXX], 2024, the rear windshield/liftgate glass spontaneously shattered without any apparent cause. The vehicle was merely six months old at the time of the incident. This unexpected and potentially hazardous occurrence has prompted me to investigate further, and I have come across multiple reports online from other customers who have experienced similar issues with the same rear windshield/liftgate glass on this specific vehicle model. This pattern of incidents raises significant concerns about a potential manufacturer's defect that may compromise the safety and reliability of these vehicles. Given the frequency of such occurrences and the potential safety implications involved, I am urging the National Highway Traffic Safety Administration (NHTSA) to investigate this matter thoroughly. It is imperative to identify any underlying issues or defects that may be contributing to these incidents to ensure the safety of consumers and prevent any potential accidents or injuries in the future. Please consider this complaint as an urgent matter, and I implore the NHTSA to take appropriate action to address this issue promptly. Your attention to this matter is greatly appreciated, and I look forward to a swift and comprehensive investigation into this concerning issue. Sincerely, [XXX] [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11589209

Incident

Apr 26, 2024

There is a serious vibration or bouncing of the hood that is very distracting while driving once the vehicle is moving 40 mph or more. My guess is that the metal is too thin or not well bracketed causing it to flutter or vibrate from airflow over the hood. I also experienced the hood denting in from a strong wind gust that made a very loud bang or pop making me think the hood was about to blow off and had to immediately pull over to examine but nothing seemed to be wrong. It just must have dented in and out again. Seems very dangerous. It flutters every time you drive the vehicle above certain speeds and causes the sunlight to flicker in your face which is very distracting. It is evident with every road test.

NHTSA ID

11574818

Incident

Feb 29, 2024

The rear portion of the hood, closest to the windshield vibrates or flutters at speeds above 30 MPH. At speeds above 50 MPH the flutter becomes very noticeable and actually reflects sunlight into the driver's field of vision. I had personally been blinded by this for several seconds - a very dangerous situation on a busy interstate highway. Fortunately the vehicle's lane keeping assist kept me in the lane but I otherwise could very easily have swerved into another car or rear-ended a stopped vehicle. I have taken this vehicle to my local dealer and a technician reproduced the problem very easily. I was told by the service manager, however, that this is a normal condition for this vehicle and suggested I contact Toyota.

NHTSA ID

11573707

Incident

Feb 7, 2024

The entire proximal portion of the hood closest to the windshield vibrates above 50 mph. Windy conditions make this worse. The glare on the hood will vibrate distracting the driver. I have reported this to Toyota and they do not care to acknowledge it as a problem. There are forums of new honors of the Grand Highlander complaining. My dealership could reproduce the problem and said there is no fix.

NHTSA ID

11571899

Incident

Jan 10, 2024

The hood vibrates at 50mph on the back 1/4 th closest to the windshield. It’s very distracting while driving. I also had an incident where adaptive cruise control in light rain did not appropriately anticipate traffic up head and I had to slam the brakes myself.

NHTSA ID

11564084

Incident

Jan 3, 2024

Hood vibrates, and on sunlight or cloudy days the light flickers in your vision. This is a safety concern that Toyota says is a normal characteristic of the vehicle. NOT.

NHTSA ID

11552857

Incident

Oct 1, 2023

Hope this email finds you well. I am writing just to give some feedback about my brand new Grand Highlander Platinum. Unfortunately, I have been noticing some issues with the hood (vibrating) at any speed which raised a huge concern about the safety of my family as it seems like the hood is going to fly away from the vehicle (at high speed like 50 mph or more). The formal response received from 2 different dealers is: We just got off the phone with the Toyota technical specialists about the concern with the hood. They have one other case open for the same complaint but are telling us there is no safety concern at this time and to release the vehicle back to you. We did test 2 other Grand Highlanders and they are both doing the same thing. My personal opinion is that due to the lightweight nature of the hood it is susceptible to flex and is showing that movement more obviously because of the black paint’s reflection properties. In my experience, if more of these cases arise, the manufacturer will open an investigation into a possible resolution but at this time we have been instructed to take no action. If you want I can send you some videos about the vibration. As you can see, the answer does not make sense since it is uncomfortable to see how the hood moves while you drive. I think it is important that customers know this defect before investing money in this vehicle. Kind regards, [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11551537

Incident

Oct 13, 2023

I wanted to open the hood using the hood support rod. Holding the hood with left hand using right hand grabbed the support rod . It burned my fingers immediately.Looking at the designed it is placed in the center of the hood underside right above engine compartment.It took one week and 3 phone calls to Toyota product liability area. I told him I learn my lesson the hard way that I will never grab it again without a glove. It is that hot I asked him why would they design a bar above the engine compartment which will except all the heat from the engine, I looked in the owners manual and I read it to the Toyota person I contacted and this is what it says and I quote the support rod may be hot after driving the vehicle. Touching the hot support rod may lead to burns or other serious injuries so I told the representative at Toyota they put this in the book knowing that people are going to get burned or drop the hood when their hand gets burned and it’s gonna fall on their head or it’s going to hit their hand. Why would they design something so poorly like this he thanked me for letting him know about it I asked him what will someone be back in touch with me to validate my concern and that they’re looking into it and he said absolutely not he said if there’s any recall, I’ll get notified by mail. Thank you very much is all I got from them

NHTSA ID

11549288

Incident

Oct 3, 2023