2009 Toyota Highlander

On November 16, 2018, the Office of Defects Investigation (ODI) opened an Engineering Analysis (EA18-006) as an upgrade to a Preliminary Evaluation (PE18-005).  The investigation focused on allegations of steering wheel separation from the lower steering column after using the tilt and/or telescoping mechanism. Given the separation occurring when operating the tilt and/or telescoping function and failure of both shear capsules to maintain the lower steering column mounting position, potential for shear capsule damage in the known failures due to collisions, the overall low rate of occurrence, and the updated manufacturer documentation, this investigation is closed.  The closing of this investigation does not constitute a finding by NHTSA that no safety-related defect exists.  The agency reserves right to take further action if warranted by the circumstances. A detailed summary of the investigation is attached to this closing resume. To review the ODI reports cited in the Closing Resume ODI Report Identification Number document, go to NHTSA.gov.

On May 4, 2018, the Office of Defects Investigation (ODI) opened Preliminary Evaluation PE18-005 to investigate three allegations of steering column separation for Model Year (MY) 2008 through 2013 Toyota Highlander vehicles. Two (2) of the 3 complaints were received by ODI in April 2018 and occurred while the vehicle was in motion. Since opening PE18-005, one (1) additional VOQ involving steering column separation has been received. This incident occurred while the vehicle was stationary.As part of PE18-005, ODI examined the field data, warranty data, and relevant technical information submitted by Toyota in response to the PE18-005 information request letter. Ten (10) additional incidents of steering column separation were identified. Four (4) of these instances occurred while driving. During PE18-005, ODI confirmed that the steering columns in the subject vehicles are equipped with breakaway capsules that are designed to collapse/shear during certain types of vehicle collisions. This design feature aims to reduce driver injury severity from impact with the steering wheel in frontal vehicle collisions. There is no direct method for detecting when the capsules in the subject vehicles have sheared. If the driver operates the tilt/telescoping feature after the breakaway capsules have separated, the steering column may drop out of position and could subsequently detach entirely from the rest of the steering assembly. Loss of steering while driving may cause a loss of vehicle control, which could lead to a vehicle crash.To date, ODI has identified 14 incidents involving complete steering column separation, 6 of which occurred while driving. One of these incidents involved a minor crash. Additionally, there have been 16 events where the steering column dropped from the dashboard mounting brackets, but column separation did not occur. Four of these incidents happened while driving. Of these 30 total separation/drop incidents, 5 of the vehicles have evidence of minor collision repairs months or years prior to the steering column failure.This investigation has been upgraded an to Engineering Analysis (EA18-006) in order to 1) conduct a more detailed analysis of the conditions that may cause the steering column breakaway capsules to separate and 2) assess factors that may contribute to the problem of failing to detect and repair breakaway capsules after they have separated. Toyota has recently revised their repair manual and issued a Collision Repair Information Bulletin to help address the second concern.The VOQs associated with this investigation can be viewed at www.NHTSA.gov under the following ODI complaint numbers: 11141761, 11083623, 11083280, 10888043.

The contact owns a 2009 Toyota Highlander. The contact stated that while driving at an undisclosed speed, the vehicle made an abnormal, loud clunking sound. The ABS, the parking brake, and the traction control warning lights were illuminated. The vehicle was taken to an independent mechanic, where it was diagnosed that the brake actuator assembly had failed and needed to be replaced. The vehicle was not repaired. The dealer was not contacted. The manufacturer was made aware of the failure. The failure mileage was approximately 137,000.

NHTSA ID

11677249

Incident

Jul 30, 2025

Mileage

137,000 mi

1. Component/System that Failed: The component that has malfunctioned is the ABS actuator, which affects the vehicle’s anti-lock braking system. The issue has been diagnosed and confirmed by two independent repair shops. The vehicle is available for inspection upon request. 2. Safety Risk: This issue has placed my safety—and the safety of others—at serious risk. There have been multiple situations where I feared I would be unable to stop in time, especially during sudden stops at red lights, heavy traffic braking, and even a brake check from an aggressive driver. The brakes feel inconsistent and make loud noises during hard braking. I transport my child in this vehicle regularly, and the fear of losing braking ability in an emergency is deeply unsettling. 3. Confirmation of Problem: Yes, the problem has been confirmed by two independent service centers, both of which diagnosed the issue as a known ABS actuator failure. They informed me that this is tied to a Toyota Customer Service Bulletin and recommended I contact the manufacturer for further assistance. 4. Inspection by Others: I contacted Toyota directly through their national customer service line and also visited a Toyota dealership in Dover, Delaware. Both confirmed that my vehicle was outside the coverage range of the CSP due to the 10-year limitation and refused assistance. I do not believe this is fair since the extension was granted right before Covid, which shut down the ability to get vehicles serviced for almost 2 years! This is unfair and needs to become a full recall. 5. Warning Signs and Timing: The warning indicators for the issue—the ABS light and VSC (Vehicle Stability Control) light—first appeared approximately two months after I purchased the vehicle in August 2024. Along with the warning lights, though my braking ability has severely declined recently. I would like Toyota to either help me get my vehicle safe or make this a real recall so that you don't risk loss of life over brakes.

NHTSA ID

11653771

Incident

Apr 9, 2025

My airbag light came on and I don't understand why the airbag light came on. I took it to a auto shop and they said I would have to take it to a Toyato dealer. Also, my emergency brake is all the way to the floor and it has never released. It will not release at all. It has been that way ever since I bought the vehicle.

NHTSA ID

11620896

Incident

Dec 10, 2022

the ABS pump and actuator on this vehicle have failed. The warning lights on dash indicate ABS, BRAKE, TRACTION CONTROL, and (!). Toyota knows that the actuator on over one hundred thousand vehicles has an internal leakage (which can not be seen on visual inspection). I have requested Toyota to repair and replace this manufacturing malady and Toyota has declined any assistance.

NHTSA ID

11581357

Incident

Mar 27, 2024

245/55R19 is the tire size. I went to have my tires balanced and aligned on [XXX] at a local shop, Arrow. Alignment here in Eau Claire, WI. They advised me that the ply in all 4 tires was separating and that is why the ride was so rough. Presently I’m scheduled to have them all replaced to the tune of $1,034 and change this Friday, [XXX] at arrow alignment because although the tread - confirmed at a dealership to still be good - the tires themselves seem to have some sort of defect in them causing them all to have the ply separating. I’ll have them check the spare this Friday as well to ensure that is not also experiencing ply separation and if it is have that replaced as well. Fortunately this didn’t cause a horrid accident, but I’ve been driving on these at high speeds assuming I just had to get them aligned and balanced. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11571720

Incident

Feb 9, 2024

Brakes failed at a low rate of speed despite pumping them and pushing the petal all the way to the floor. Several witnesses in the car support this narrative. Vehicle ended up slowly rolling into the car in front of us. Minimal damage to both. Took it in to the dealership and they said the brakes appear fine.

NHTSA ID

11570822

Incident

Feb 1, 2024

The contact owns a 2009 Toyota Highlander. The contact stated that the power window master switch inoperable. The contact referenced NHTSA Campaign Number: 15V689000 (Visibility). There were no warnings lights illuminated. The vehicle was taken to dealer. The dealer stated that the power window master switch needed to be replaced. The vehicle was not repaired. The manufacturer was not contacted. The failure mileage was 127,000.

NHTSA ID

11563043

Incident

Jun 1, 2010

Mileage

127,000 mi

2009 Toyota Highlander Hybrid; mileage 97,849. While driving a red BRAKE alert showed up along with an ABS light, traction symbol and an encircled exclamation mark. This malfunction (which I now see is a known safety issue) shut down my regular braking system and I had to use the emergency brake to stop. A message appeared telling me to pull over to a safe spot and contact my dealer. A shrill high pitched sound also went off. How can a faulty designed ABS module that blocks the braking system from working when it fails not be under a safety recall - just an expired Safety Bulletin? I was fortunate to think to use my emergency brake to stop to avoid an accident and injury to myself and/or others. Vehicle was towed to Gates Toyota, South Bend, IN. if you wish to contact them regarding codes & costly repair bill expenses. I have a call in to the Toyota Headquarters Resolution Team and am waiting for them to contact me back on my case.

NHTSA ID

11562715

Incident

Dec 13, 2023

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.

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.

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.

Toyota vehicles are currently protected with RapgardTM protective film designed to protect the horizontal painted surfaces. This material protects from acid rain, environmental fallout, and rail contamination. Follow the Removal Procedure in this bulletin to remove the RapgardTM protective film within 90 days from initial application.

Vehicles may occasionally be subjected to contamination by airborne iron particles shed from railroad tracks, train wheels, exposure to heavy machinery facilities, grinding, welding, etc. This type of contamination can be identified by the presence of small, red or brown particles on the paint surface. These particles are often difficult to see on dark color paints but can be easily felt when brushing a hand across horizontal body surfaces such as the hood, roof, or deck lid. Follow the Repair Procedure in this bulletin to clean vehicles that may have been subjected to contamination by airborne iron particles such as rail dust during rail transportation or extended storage near industrial areas.