2022 Toyota Highlander

This complaint concerns the administration of an EXISTING federal safety recall, NHTSA 24V-419 / Gulf States Toyota 24R1, not a new defect. My 2022 Toyota Highlander was equipped with tires later recalled because they had an insufficient load rating. I experienced premature tire wear and, on June 8, 2024 at approximately 41,300 miles, I paid $1,225.50 out of pocket to replace all four tires. At that time I had not received any recall notice. Gulf States Toyota later required the tires on my vehicle to be replaced again under Recall 24V-419 because the vehicle was covered by the recall and the tire configuration had to be corrected. The original tires are no longer available for inspection because they were replaced. The safety issue was the insufficient tire load rating identified by the recall, which could increase the risk of tire failure. There were no warning lamps or dashboard messages before the tire wear. I submitted a reimbursement claim to Gulf States Toyota for the June 8, 2024 tire replacement. GST denied it with the statement: “Repair Did Not Remedy Recall Condition: The repairs performed on your vehicle did not remedy the specific condition outlined in the recall notice.” My concern is that GST did not substantively address my pre-notification reimbursement claim or explain why the expense does not qualify under its recall reimbursement plan. The tire replacement occurred before I received notice, and GST later replaced the tires again because it was required to perform the recall remedy. I am asking NHTSA to review Gulf States Toyota’s administration of Recall 24V-419 and its handling of pre-notification reimbursement claims under 49 CFR § 573.13. Please document this as a recall-administration/reimbursement issue associated with existing Recall 24V-419.

NHTSA ID

11765890

Incident

Jun 8, 2024

The contact owns a 2022 Toyota Highlander. The contact stated that while the vehicle was parked, the tailgate glass exploded due to the heat and fell inside the vehicle. The Toyota manufacturer corporate office was contacted. The vehicle was taken to the local dealer. The glass was replaced by Safelite. The approximate failure mileage was 55,656.

NHTSA ID

11765766

Incident

Sep 9, 2026

Mileage

55,656 mi

Vehicle begin making grinding noises, and stalling during accelerating and also fuel smell. Took vehicle into Toyota Waldorf, MD dealership for diagnostic. At 58,000 miles, 2022 Toyota Highlander XLE stalls to accelerate due to front differentials failing, causing large chunks of metal on the drain plug indicating internal failure. Vehicle needs transmission and front differential replaced. I have 4 children, 3 of them still small, and driving with the fuel smell would impact them greatly as 1 of my children has asthma. It's also a hazard to be on the road with this vehicle as it can stall at any moment, causing a traffic incident. The problem has been reproduced by dealer, who is refusing to approve the fix under the 60,000 mile Power Train Warranty. There were no other warning signs, no check engine light came on, no issues prior to me hearing this grinding noise and stalling.

NHTSA ID

11765724

Incident

Aug 14, 2026

Vehicle begin making grinding noises, and stalling during accelerating and also fuel smell. Took vehicle into Toyota Waldorf, MD dealership for diagnostic. At 58,000 miles, 2022 Toyota Highlander XLE stalls to accelerate due to front differentials failing, causing large chunks of metal on the drain plug indicating internal failure. Vehicle needs transmission and front differential replaced. I have 4 children, 3 of them still small, and driving with the fuel smell would impact them greatly as 1 of my children has asthma. It's also a hazard to be on the road with this vehicle as it can stall at any moment, causing a traffic incident. The problem has been reproduced by dealer, who is refusing to approve the fix under the 60,000 mile Power Train Warranty. There were no other warning signs, no check engine light came on, no issues prior to me hearing this grinding noise and stalling.

NHTSA ID

11765723

Incident

Aug 14, 2026

UNKNOWN CONCERNED THE SAFETY WARNING HAS BEEN ISSUED SINCE 3/5/26. AS OF TODAY (9/13/26), THE PROBLEM HAS NOT BEEN SOLVED

NHTSA ID

11764748

Incident

Sep 16, 2026

I would like to file a complaint regarding Toyota’s known brake surge issue addressed in Technical Service Bulletin T-SB-0059-23. I believe this is a serious safety issue because the unexpected braking or brake surge when stopping can potentially cause a driver to lose control of the vehicle or contribute to an accident. I contacted a Toyota dealership near me about the issue, but they were unwilling to provide any assistance. I then contacted another Toyota dealership, which informed me that they could perform the repair but would charge approximately $400. I am concerned that Toyota has identified and documented this issue through T-SB-0059-23 but does not provide the repair free of charge unless the vehicle is still within the 36,000-mile warranty period. A known safety-related defect should not necessarily become the customer’s financial responsibility simply because the vehicle has exceeded the mileage limitation of the basic warranty. I am requesting that Toyota review this matter and consider providing the repair at no cost, particularly given the safety implications of the brake surge issue and the fact that Toyota has already acknowledged the condition through its technical service bulletin.

NHTSA ID

11764432

Incident

Oct 1, 2025

The contact owns a 2022 Toyota Highlander. The contact stated that while driving at an undisclosed speed around an S-curb, the vehicle jerked into the nearby lane. The local dealer was contacted. The failure mileage was approximately 55,000.

NHTSA ID

11764306

Incident

Sep 11, 2026

Mileage

55,000 mi

Wind shield seemed to crack spontaneously and it continued to grow over several days until the crack went from one edge to another.

NHTSA ID

11764200

Incident

Sep 10, 2026

Some 2020 – 2026 model year Highlander and Highlander Hybrid vehicles may exhibit a water leak from the roof rack attachment clips. This may be caused by the sealant in the roof channel obstructing the proper seating position for the clip gasket.

Some 2020 – 2024 model year Highlander and Highlander Hybrid vehicles may exhibit a condition in which the air conditioner does not cool due to a leak and/or corrosion in the rear underbody air conditioner tube and accessory assembly. The anti-corrosion material has been updated to reduce the possibility of this condition.

OBSOLETE NOTICE January 30, 2026: This bulletin is now obsolete. Please see T-SB-0001-26.

Some 2018 – 2024 model year Toyota vehicles equipped with a Premium Audio with Dynamic Navigation System require a Special Service Tool (SST) USB flash drive to update the map, points of interest, and system software.

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.

Some 2020 – 2023 model year Highlander and Highlander Hybrid vehicles may exhibit a condition in which the Power Back Door (PBD) will not open or close and/or stops moving while opening or closing. A modified PBD unit assembly is available to address these conditions.