2026 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.

A rock or large insect went through the massive openings on the car’s front grille and went through the condenser destroying the air conditioning system in the car. This issue was confirmed by the insurance adjuster and a Toyota dealership and local repair shop. Both confirmed the issue was likely due to the large openings in the grille. The part is not available for inspection, as it has been replaced by a Toyota dealership, however Toyota did not consider this warranty work and I had to pay for the repair out of pocket even though the car was less than a year old.

NHTSA ID

11777399

Incident

Jun 9, 2026

On September 10th 2026 a cracked windshield was replaced by PAULY TOYOTA in Crystal Lake. The re installed windshield is unsafe/defective. I reported the problem to the dealership and TOYOTA corporate. I went back to the dealership 3 times, they cleaned the windshield and stated it was my washer fluid and after refilling with shop washer fluid its all good. Then they said it is the outside influence. It was also inspected by certified, independent glass company that confirmed that the windshield is defective and needs to be replaced because its unsafe. THe corporate officially refused to replace it.

NHTSA ID

11776899

Incident

Sep 11, 2026

I was traveling while on cruise with the max distance set between another vehicle and I. A rock popped up and managed to propel itself through the poorly designed and inadequately designed grill and into my condenser. I am apart of many Highlander support groups and this seems to be an issue with a lot of people. They have to take it upon themselves to install a mesh to prevent road debris entering through their grill. This could have been a significant safety issue had it been my radiator. Now I am out $2,000 due to faulty design on Highlander grill and I haven’t even made my first car payment yet.

NHTSA ID

11776862

Incident

Nov 5, 2026

I am filing a safety complaint for a severe steering/drivetrain defect causing dynamic alignment deflection, unexpected braking feedback, and a vehicle control hazard on my 2026 Toyota Grand Highlander (16k miles). The vehicle has a severe rotational grumbling noise under low acceleration and right after letting off the brake. On braking, a violent mechanical "thunking" noise occurs in the front chassis. The brakes also exhibit a distinct physical grinding sensation through the pedal under normal stops, despite a formal inspection confirming pads, rotors, and calipers are free of defects. The steering geometry is entirely unstable. At 10,144 miles, an alignment sweep showed the settings were within factory specs, yet all four factory tires were completely feathered with severe tread destruction. By 15,000 miles, the front left toe violently drifted out of specification by 0.20° (shifting from a near-perfect 0.04° to a severe 0.24°). This massive structural alignment shift occurred in under 5,000 miles of normal driving without any road impacts. Compounding these issues, a drain/inspection of the front differential housing at 16,000 miles revealed the factory gear fluid is completely black, burnt, and opaque, with a heavy layer of dark metallic sludge coating the magnetic drain plug. This confirms severe friction, binding, and premature mechanical breakdown within the front drivetrain assembly. Both the Toyota dealership network and Toyota corporate customer service have been presented with this mathematical alignment data and degraded fluid evidence. They flatly refuse to diagnose the root cause, inspect the steering knuckles/axles under warranty, or perform repairs, claiming the vehicle's condition is "normal." I am trapped driving an unsafe, unserviced vehicle with active steering geometry collapse.

NHTSA ID

11776839

Incident

Oct 19, 2026

Unprotected Grill A/C system. A rock can go straight through the grille and puncture the condenser.

NHTSA ID

11776744

Incident

Nov 9, 2026

Rear moonroof glass shattered spontaneously, no object impact

NHTSA ID

11776020

Incident

Nov 4, 2026

Experiencing a cabin boom. Low frequency noise and car is changing cabin pressure. Happening when going slower and over bumps or imperfections in the road. Causing severe ear pain to the point the car is not drivable. Toyota saying it is known and normal for the vehicle and will not fix it.

NHTSA ID

11775892

Incident

Oct 16, 2026

Air Conditioner Failed after a small debris hit the condenser. Defrost does not work when AC fails. Dealer confirmed small debris punctured condenser. Claim was filed with insurance for repair and inspection. No warnings AC stopped working and windows fogged.

NHTSA ID

11775189

Incident

Oct 30, 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.

2026 model year Toyota vehicles are equipped with driver side floor mat retainers to secure the floor mat in the correct position. In addition, some models may also utilize retainers for passenger side and rear seat floor mats. During Pre-Delivery Service (PDS), follow the appropriate Installation Procedure to attach the driver side, and if applicable, the passenger side and rear seatfloor mats to the vehicle carpet using the floor mat retainers.

During the manufacturing process, tires are mounted on the vehicle as matched sets to help reduce conditions such as pulling or drifting. If the wheels are replaced or refinished before vehicle delivery, it is important that the tires remain on the vehicle in the same location and in the same direction of rotation.

A battery in a stored vehicle is subject to conditions that can reduce its performance and service life. These conditions include storage period, temperature, parasitic drain, and battery load. Because of these factors, battery inspection and maintenance are required in order to ensure proper operation and optimal battery life.

Long-term or off-site storage requires special care to maintain vehicle condition. The following guidelines should be performed to minimize vehicle component/part degradation due to extendedvehicle storage conditions. Long-term storage can affect a vehicle’s systems and components. Any problems that are found should be corrected immediately.

Pre-Delivery Service (PDS) is a critical step in satisfying our new car customers. Customer feedback indicates the following areas deserve special attention when performing PDS: • Careful inspection for paint chips/scratches and body dents/dings. • Proper operation of electrical accessories (including interior light, clock, and radio reset). • Interior cleanliness. • Proper function of mechanical systems. The PDS process helps identify potential vehicle concerns before customer delivery. After completing the PDS process, maintain accurate PDS records by ensuring the required documents listed below are completed and recorded in accordance with Toyota Warranty Policy. • GTS+ Health Check • Completed PDS Check Sheet • Battery Charge Test Print Out • GTS+ Tire Pressure Information Customer retention and proper maintenance of vehicles are and have always been a major focus for Toyota. To help remind customers that regular service is essential to the proper maintenance of the vehicle, dealers are required to install a service reminder sticker before delivery. By doing this, customers will be reminded to return to your dealership for service. Your current service reminder sticker may be used. This bulletin contains the PDS procedures that apply specifically to 2026 model year Grand Highlander and Grand Highlander Hybrid vehicles.