2011 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.

Odometer Fraud. The contact purchased a 2011 Toyota Highlander. It was discovered that there was a mileage discrepancy. The vehicle was a private sale but contacted by a dealer. At the time of purchase, the vehicle mileage was 122,000, and at the time of registration, it was discovered that the mileage was 303,000.

NHTSA ID

11742114

Incident

Sep 14, 2025

Mileage

303,000 mi

1. The 3.5L V6 Engine (2GR-FE) failed due to the subsequent loss of lubrication caused by the rupture of the Oil Cooler Pipe (Rubber component), a manufacturing defect known under TSB T-SB-0201-11 (ZE2 Program). The failed engine is currently available for inspection by request at the independent service center before it is disposed of. 2. The defect causes a sudden and severe loss of engine oil. This creates a high probability of the engine seizing (losing all power) while driving at highway speeds, resulting in a complete loss of propulsion and placing occupants at severe risk of collision. 3. The failure was confirmed, not reproduced. The vehicle was initially diagnosed with misfire codes (P0300, P0301). New spark plugs and ignition coils were installed in an attempt to resolve the issue. As the misfire persisted, the mechanic performed a compression test, confirming catastrophic zero compression failure in cylinders 1 and 2. Professional diagnostics then revealed critical codes: P1603 (ECM Malfunction), P1604 (Startability Malfunction), and P1605 (Rough Idling). These codes confirm a severe internal engine issue, consistent with permanent damage sustained during the oil loss event caused by the ZE2 pipe defect in July 2024. 4. No, not physically inspected by the manufacturer. The manufacturer (Toyota Executive Office Case Manager) was provided with certified documentation of the failure, including the photo of the faulty pipe, maintenance records during our ownership, and the dealership purchase statement for the replacement part. Toyota refused to authorize a physical diagnostic inspection of the failed engine at a dealership before denying goodwill assistance. 5.Yes. The initial lubrication loss event on July 4, 2024, was preceded by a message displayed on the dashboard (followed by a second failure event in October 2025 indicated by a flashing Check Engine light and the Traction Control light).

NHTSA ID

11701620

Incident

Oct 8, 2025

Steering wheel air bag did not deploy in front end MVA

NHTSA ID

11619420

Incident

Oct 9, 2024

Our car had a major oil leak from the engine Oil Cooler Pipe Manifold at the bottom of the engine (front). My research has concluded that this has been a known issue with various Toyota models with the 2GR-FE engine, however Toyota has not issued a recall and the local dealership has never mentioned it during services. The NHTSA has known about this issue, however it appears that little to no action has been taken with the vehicle manufacturer or public. The issue concerns a leak that is waiting to happen on all engines with the original Oil Cooler Pipe as it is designed with rubber pipes that degrade over time and even a pin hole oil leak will cause virtually all the engine oil to drain from the engine onto the pavement below and underside of the vehicle including brake components. It is not a matter of “if” but “when” it will happen, and the consequences can leave people stranded with a damaged engine and undriveable vehicle. Severe injury and deaths can and will result due to the ongoing lack of action by the NHTSA and vehicle manufacturer. As an aside, the cost to repair is in the thousands of dollars, unless the owner is fortunate like myself who was able to replace the Oil Cooler Pipe at my own time and cost with the vehicle out of service and significant clean up required. I still don’t know the long-term effects of our engine being almost drained of oil and because of this may now sell the car which was not in our plan. I have added a photo of the original inadequately designed Oil Cooler Pipe and the replacement version purchased from Toyota. Also, the dealership were not interested in doing anything for us. I demand that the NHTSA takes action which is long overdue. Please take this issue seriously

NHTSA ID

11596623

Incident

Jan 17, 2024

Dear Sir/Madam, I am writing to file a formal complaint regarding persistent safety issues with my 2011 Toyota Highlander V6 AWD. Specifically, I have experienced significant problems related to the engine timing guide, timing chain, transmission system, which pose a risk to both vehicle occupants and other road users. Vehicle Information: Toyota Highlander V6 AWD, VIN: [XXX] Description of the Issue: The transmission in my Highlander has exhibited the following problems: 1) Low engine oil pressure, ticking Noise: There is low engine pressure, faulty guides timing chains, recurring ticking noise. This noise represents issues from the powertrain area and has raised concerns about potential mechanical flaws1. 2) Defective components, slipping Transmission: The transmission surges/slips affecting overall control and safety. This issue has been reported by other Highlander owners as well. Cross-Referencing Other Complaints and Recalls: 3) They did not go far back, Per the NHTSA database, there have been two documented complaints related to transmission issues in the 2011 Toyota Highlander V6 AWD, these complaints align with my experience, however they have not sent me the recall notice. In fact, Toyota has faced recalls and technical service bulletins (TSBs) related to transmission problems in various Highlander models: The 8-speed UA80E/UA80F automatic transmission used in the 2020 Highlander received a TSB for shift flare during wide-open throttle acceleration from 40 – 60 mph and during the upshift from 2nd to 3rd gear. Toyota addressed this issue under warranty1. The 6-speed U660F/U760E automatic transmission, used in earlier Highlander models, was generally reliable. However, the introduction of the 8-speed UA80E/UA80F unit caused initial problems1. Request for Action: Per NHTSA findings please ensure all the models sharing the chassis, model family, part and Toyota transmission oil are included in recall or service campaign. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C.

NHTSA ID

11590714

Incident

May 2, 2024

the intake VVT-i gear on 2AR-FE equipped Rav-4s and other Toyota models Has failed after 113k miles. The vehicle is at risk of causing self inflicted damage due to this common issue many toyota owners are facing 2008-2013 highlanders. The part has not been inspected but was diagnosed by a mechanic based on their past experience with these vehicles and sound. No warnings or dash lights just a terrible metallic rattle upon cold start. This started around 2k miles ago.

NHTSA ID

11542525

Incident

Jul 19, 2023

As my family was driving down Interstate 85 in Atlanta going around 80 MPH a dash notification came on that said "Low Oil Pressure pull over" the notification came on then went away then came back on (car never ran hot). Thankfully we were near an exit so we pulled off and into the first parking lot we could find. There was a huge puddle of oil under the car and smoke coming from the engine. We got our Highlander towed back to our nearest Toyota dealership to our home to be inspected. It was discovered our Engine Oil Cooler Pipe had failed resulting in all of the oil in our car being released from the car. If we hadn't been able to pull over so fast most likely my engine would have seized up and caused a wreck in the middle of the interstate. After doing research on this issue I discover there was a Warranty Enhancement Program done by Toyota on this very part valid through 2021 or 150,000 miles. I have 163,000 miles on my car. I tried to explain to Toyota that like majority of people my car was not driven for 2 years due to covid so they should at the very least expand the warranty. The dealership also told me they couldn't have replaces the part until it failed which from what I can tell of the hundreds of other Toyotas experiencing this same issue there are no warning signs prior to the part failing, you discover it failed by it releasing all your oil while driving at a high rate of speed.

NHTSA ID

11513598

Incident

Mar 18, 2023

Pin hole in oil line causing excessive oil leak. Loose oil very quickly. Could cause permanent damage to engine. Had old line replaced by mechanic with a metal line only inspected by my mechanic and there was mention of past recall by my mechanic but it does not show this on your sight. There was no warning lights at all. A coworker noticed excessive oil on the ground when I left work and called me immediately to check oil. Very little left in engine and I could see it coming from under car. Incident happen on 1-9-2023 Had car towed to mechanic to avoid damage to engine. My issue was there a recall at some point ? If other Toyotas are having this issue need to be addressed before cars blow there engines from no oil ! Since no warning lights came on I would have no idea I was losing oil this fast just driving down the road! I only knew because my coworker saw massive spill on concrete at work .

NHTSA ID

11501313

Incident

Jan 9, 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.