2007 Toyota Highlander Hybrid

NHTSA received a petition on or about July 18, 2022, requesting that Federal Motor Vehicle Safety Standard (FMVSS) 141 be applied to all electric and hybrid vehicles operating in the United States. The petition can be reviewed at NHTSA.gov under ODI Number 11486072. FMVSS 141 establishes performance requirements for pedestrian alert sounds for motor vehicles. The standard applies to hybrid and electric vehicles that have a gross vehicle weight rating of 4,536 KG or less or are defined as low-speed vehicles. The standard became fully applicable to all such vehicles manufactured on or after March 1, 2021.On January 27, 2023, NHTSA opened Defect Petition (DP) 22-005 to evaluate the subject matter described in the petition. On June 24, 2023 and as supplemented on June 25, 2023, the petitioner notified NHTSA he was withdrawing his petition. The petitioner indicated that, based on his review of data, there is no justification for asserting potential benefits that could be derived from actions sought by my petition. Based on the petitioner's withdrawal, DP22-005 is closed. Closure of this DP does not represent a determination by NHTSA regarding the subject matter of the petition.

In a June 29, 2011 letter to NHTSA, Toyota submitted a Defect Information Report regarding a safety recall of certain Toyota Highlander Hybrid and Lexus RX400h vehicles to address a defect condition with the hybrid inverter assembly (NHTSA Recall No. 11V-342).Toyota's letter identified a defect related to inadequately soldered transistors on the Intelligent Power Module (IPM) of some of the subject vehicles that could result in sudden loss of power while driving.Toyota's remedy procedure instructs dealers to inspect the hybrid inverter production number to determine if the inverter contains suspect transistors.If so, the dealer will replace the IPM.The recall covers approximately 45,528 model year (MY) 2006 and 2007 Toyota Highlander Hybrid vehicles manufactured from February 16, 2005 through August 29, 2006 and approximately 36,745 MY 2006 and 2007 Lexus RX400h vehicles manufactured from February 23, 2005 through August 30, 2006.This Preliminary Evaluation is closed.

The contact owns a 2007 Toyota Highlander Hybrid. The contact stated that upon starting the vehicle, several unknown warning lights were illuminated. The vehicle was towed to the dealer where it was diagnosed with a drained battery. The dealer determined that the battery needed to be replaced. The vehicle was repaired; however, the failure recurred. The vehicle was towed to the dealer where it was diagnosed with an ABS actuator malfunction, and the ABS actuator was replaced. The failure recurred and the ABS actuator was replaced a second time. The contact stated that the brake pedal needed to be depressed multiple times for the brakes to respond as needed. The vehicle was taken back to the dealer where it was diagnosed with ABS actuator malfunction for the third time. The vehicle was not repaired. The manufacturer was made aware of the failure. The failure mileage was approximately 96,153.

NHTSA ID

11580780

Incident

Dec 5, 2018

Mileage

96,153 mi

The contact owns a 2007 Toyota Highlander Hybrid. The contact’s son stated while driving approximately 70 MPH, the vehicle lost motive power and stalled. The contact stated that several unknown warning lights were illuminated. The vehicle was towed to the contact’s residence. The vehicle was not taken to a dealer to be diagnosed. The manufacturer was informed of the failure and informed the contact that the VIN was not under recall. The failure mileage was approximately 196,000.

NHTSA ID

11449033

Incident

Jan 24, 2022

Mileage

196,000 mi

I REPLACED MY BRAKES AFTER SEVERAL WARNING LIGHTS AND CODES KEPT POPPING UP ON MY DASH. HAD THE ROTORS TURNED. BUT WHEN I RETURNED TO DRIVING MY CAR AFTER I THOUGHT IT WAS FIXED THE BRAKES WOULD ALL OF A SUDDEN JUST GO OUT THE HYDRAULIC PART WOULD GO COMPLETELY TO THE FLOOR. THE CAR WOULD MAKE A HIGH PITCHED NOISE AND THEN NO BRAKES. TOOK IT TO TOYOTA IN CLINTON TN. SAID MY ABS BRAKE ACTUATOR WAS FAILING. WOULD COST ME 2200 DOLLARS TO FIX. THIS CERTAIN PART ON YOUR CAR IS SUPPOSED TO LAST YOU A LIFETIME. I DONT HAVE MONEY LIKE THAT NOW IT WAS TAKE ME A LIFETIME TO SAVE UP FOR THE REPAIRS. VERY SCARY. THIS WOULD HAPPEN TO ME RANDOMLY AS I WAS DRIVING NO MATTER WHERE OR HOW FAR THE TRIP I WAS TAKING. DIDN'T KNOW IF I WAS GOING TO BE ABLE TO MAKE IT HOME SOMETIMES. YOU JUST NEVER KNEW WHEN. SOMETIMES IT WOULD BE FINE AND OTHERS IT WOULD BE ABSOLUTELY SCARY.

NHTSA ID

11234591

Incident

May 1, 2019

Mileage

210,000 mi

VSC LIGHT CAME ON AND THE CAR WOULD NOT DRIVE. TOWED TO TOYOTA AND HAD IT DIAGNOSED. THE POA80, P3020 HV BATTERY INOPERATIVE/SHORTED. THE VEHICLE WAS IN MOTION ON THE HIGHWAY WHEN IT HAPPENED.

NHTSA ID

11233520

Incident

May 9, 2018

Mileage

171,908 mi

THE ABS BRAKE MODULATOR BEGAN EXHIBITING VERY LOUD AND CONTINUOUS PUMPING/PRIMING SOUNDS FOR SEVERAL WEEKS. DURING THIS TIME PERIOD UPON HARD BRAKING THE BRAKE SYSTEM WOULD FAIL TO RESPOND IMMEDIATELY - THERE WAS A DELAY BETWEEN THE INSTANT THE BRAKE PEDAL WAS DEPRESSED, AND WHEN THE BRAKES WERE ACTUALLY ENGAGED TO SLOW THE VEHICLE. TODAY, ALL THE INSTRUMENT WARNING LIGHTS ILLUMINATED, INCLUDING: MASTER WARNING LIGHT, BRAKE WARNING LIGHT, ELECTRONICALLY CONTROLLED BRAKE WARNING, ANTI-LOCK BRAKE SYSTEM, AND SLIP INDICATOR. ALL THIS INDICATES A FAILURE OF THE ABS BRAKE MODULAR COMPONENT. TOYOTA MOTOR SALES, USA, INC. PUBLISHED WARRANTY ENHANCEMENT PROGRAM - ZG1 TO ADDRESS THIS ISSUE. THE WARRANTY IS ONLY VALID FOR UP TO 10 YEARS OR 150,000 MILES AND HAS RECENTLY EXPIRED FOR MY VEHICLE. TOYOTA MOTORS, KNOWING THIS COMPONENT IS PRONE TO FAILURE AND COULD HAVE CATASTROPHIC CONSEQUENCES, SHOULD TAKE A MORE PROACTIVE APPROACH TO ENSURE THE SAFE OPERATION OF ALL AFFECTED MODELS. AT PRESENT THERE IS NO WARRANTY COVERAGE, AND TOYOTA WILL NOT REPAIR THE FAULTY BRAKE SYSTEM. I AM LEFT WITH AN INOPERABLE VEHICLE WITH AN UNSAFE BRAKING SYSTEM, UNLESS I BEAR THE FULL COST OF REPLACEMENT MYSELF.

NHTSA ID

11207260

Incident

May 10, 2019

Mileage

155,000 mi

THIS COMPLAINT IS IN REGARDS TO THE TOYOTA WARRANTY ENCHANCEMENT PROGRAM ZG1. THIS WARRANTY WAS APPLICABLE FOR 10 YEARS AFTER FIRST USE OR 150,000 MILES WHICHEVER COMES FIRST. IN ORDER TO GET THE ABS ACTUATOR REPLACED A SET OF SYMPTOMS WAS REQUIRED. I OWN A 2007 TOYOTA HIGHLANDER HYBRID FWD WITH 128,000 MILES. LAST WEEK THE ABS ACTUATOR STARTED MAKING THESE LOUD NOISES AND THE ABS, BRAKE, CHECK VSC, AND MASTER WARNING LIGHT ALL CAME ON. THE BRAKING FUNCTION HAS DEFINITELY CHANGED AND NOW DOES A SUDDEN JOLT FORWARD WHEN THE CAR IS TURNED ON WHILE ALSO HEARING THE ABS ACTUATOR MAKING UNUSUAL NOISES. IT TURNS OUT THAT THE ABS ACTUATOR HAS AN INTERNAL MALFUNCTION. TOYOTA HAS TOLD ME THAT BECAUSE IT HAS BEEN 10 YEARS(EVEN THOUGH MY MILEAGE IS LESS THAN 150K), MY VEHICLE WOULD NOT BE COVERED. TOYOTA HAS ALSO STATED THAT THIS ISSUE IS A SAFETY HAZARD. I DO NOT UNDERSTAND WHY THIS ISSUE IS NOT LISTED AS A RECALL AS IT IS RELATED TO THE BRAKING SYSTEM MAKING THIS ISSUE A SAFETY HAZARD. INSTEAD I AM STUCK WITH MANY OTHERS HAVING TO PAY $3000 TO GET THE PART REPLACED EVEN THOUGH MY SPECIFIC VEHICLE IS AFFECTED BY THIS ABS ACTUATOR ISSUE. I USE THIS VEHICLE AS MY MAIN TRANSPORTATION FOR MY FAMILY. IF ANYONE CAN HELP ME OR EXPLAIN WHY THIS IS NOT A RECALL PLEASE CONTACT ME AT [XXX]. I AM LEFT WITH AN UNUSABLE VEHICLE BECAUSE MY ABS ACTUATOR DECIDED TO MALFUNCTION ON THE 11TH YEAR AFTER FIRST USE EVEN THOUGH IT ONLY HAS 128,000 MILES. IT SEEMS TO ME THAT THIS SHOULD BE A SAFETY RECALL BECAUSE OF THE CONSEQUENCES OF A MALFUNCTIONING ABS ACTUATOR. I AM REPORTING THE SUDDEN FAILING OF BRAKES AND MORE IMPORTANTLY, THE SUDDEN FORWARD JOLT THE CAR MAKES WHEN THE CAR ENGINE STARTS. I BELIEVE THAT THE ISSUES I AM EXPERIENCING IS DIRECTLY CORRELATED TO THE MALFUNCTIONING ABS ACTUATOR. AGAIN, PLEASE FEEL FREE TO CONTACT ME AT [XXX] REGARDING MY COMPLAINT. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6). *TR *TT

NHTSA ID

11205891

Incident

May 1, 2019

Mileage

128,000 mi

THE VSDC WARNING CAME ON WITH CODE C1391, WHICH MEANS THE ABS PUMP ACCUMULATOR ASSEMBLY HAS GONE BAD, WHICH COSTS THOUSANDS OF DOLLARS TO FIX. WHEN I CONTACTED TOYOTA, THEY SAID THEY EXTENDED THE WARRANTY ON THIS AND THAT EXTENSION RAN OUT A COUPLE OF YEARS AGO. HOWEVER, THIS MAKES NO SENSE TO EXTEND A WARRANTY ON A PART YOU HAVE ADMITTED IS BAD AND A SAFETY HAZARD, AS THE BRAKES WILL FAIL AFTER THIS FAULTY PART REMAINS IN THE DYSFUNCTIONAL STATE. IT APPEARS TO ME THAT TOYOTA, WAS TRYING TO APPEASE AS FEW AS PEOPLE AS POSSIBLE BY EXTENDING A WARRANTY ON SOMETHING AS DANGEROUS AS THIS. THEY REFUSE TO FIX THE PROBLEM, EVEN THOUGH IT WILL CAUSE DEATH TO MANY. THE MECHANIC SAID THIS HAS HAPPENED TO MANY TOYOTA HIGHLANDERS, PER HIS INFORMATION TOO. *JS *JS

NHTSA ID

11204883

Incident

Apr 30, 2019

Mileage

108,000 mi

A SOUND OF SQUEAKING/PUMPING AIR OCCURS SOMETIMES WHEN I DEPRESS THE BRAKES. THIS SOMETIMES CONTINUES TO HAPPEN EVEN WITH THE CAR IS STOPPED COMPLETELY. IF THE BRAKE IS DEPRESSED LESS, THE SOUND OCCURS LESS FREQUENTLY. I HAD IT INSPECTED BY AN INDEPENDENT MECHANIC AND A DEALERSHIP MECHANIC AND WAS TOLD THE ABS ASSEMBLY HAS A LEAK AND NEEDS TO BE COMPLETELY REPLACED FOR A FEE OF ROUGHLY $2,300. THIS FIRST OCCURRED WITH MILEAGE AROUND 152,000.

NHTSA ID

11181680

Incident

Jan 18, 2019

Mileage

152,000 mi

OBSOLETE NOTICE February 13, 2026: This bulletin is now obsolete. Please see T-SB-0009-26.

This bulletin includes basic procedures for performing a rescue charge on Ni-MH high voltage (HV) batteries. This bulletin should be used in conjunction with the applicable model and model year Repair Manual while performing a rescue charge. The GRX-5100 should be used wherever the Repair Manual references the Toyota Hybrid System (THS) charger.

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.

Acid rain results from rainwater or other airborne moisture that become acidic due to industrial chemical impurities in the atmosphere. If these acidic compounds settle on an exposed vehicle, especially the horizontal areas such as the hood, roof, and decklid, significant damage to the painted surfaces can occur. Acid rain damage can typically be identified on vehicles by the presence of stains on the paint surface that resemble hard water spots. Unlike water spots however, acid rain damage cannot be removed by regular washing procedures. Also, because acid rain can etch and soften the paint, normal buffing or polishing repair procedures should not be attempted. This can cause further damage and result in visible depressions in the paint surface. The following are the three major categories of acid rain damage: •Minor damage: requires only buffing to repair. •Moderate damage: usually requires neutralizing, color sanding, and buffing. •Severe damage: extending beyond 1/2 mil of clearcoat on a pearl, metallic, or solid color, requires neutralization, sanding, and repainting. In cases where acid rain damage is minor, neutralization and buffing with a liquid-type paint finessing product may provide an adequate repair. Only specially formulated products outlined in this bulletin should be used for that purpose. Unfortunately, other than minor damage, there is no simple method of determining the actual extent (depth) of acid penetration other than color sanding a representative affected area until there is no visible etching or depressions, followed by measuring the amount of paint removed with either a magnetic or digital-type film thickness gauge. The procedures in this bulletin are intended for use by qualified body/paint technicians and should not be attempted by inexperienced personnel. It is the dealer’s responsibility to protect and maintain the quality of the vehicle’s paint finish after receipt at the dealership prior to the first sale. Perform frequent vehicle washing, as often as daily, during high heat and humidity periods to minimize the potential for paint damage due to acid rain exposure. This is especially important in geographical areas known for high frequency and concentration of acid rain and industrial fallout.

To prevent brake rotor rust from forming during transportation and storage, wheel film will be used instead of a cardboard type of anti-rust cover. The purpose of the wheel film is to shield the disc brake rotor from weather elements and initial rust before the vehicle is delivered to the customer. Consequently, the film should remain on the wheel for as long as possible.

The condition known as acid rain is caused by airborne chemicals or particles in the atmosphere, which mix with rainwater, nighttime dew, or high humidity to form acidic compounds. If these contaminants settle and remain on a painted vehicle surface, especially the horizonal areas of the hood, roof, and decklid, significant damage can occur. This damage is the result of actual etching of the paint and appears as pitting or water spots. As acid rain droplets on the vehicle surface evaporate, the concentration strength of the acid increases, causing deeper and more rapid damage. This evaporation and corrosive action also occur more rapidly on dark colored cars as direct sun heat increases. It is the dealer’s responsibility to protect and maintain the quality of the vehicle’s paint finish after receipt at the dealership prior to the first sale. In areas known for high frequency and/or concentration of acid rain, frequent vehicle washing during high heat or humidity periods will minimize the potential for paint damage caused by acid rain. It is further recommended that either reverse osmosis or deionized water be used to prevent water spotting.