Summary
The Toyota Highlander has 38 recalls spanning the 2001 through 2025 model years, with the most serious recent issue being a third-row center seat belt roof anchor on 2024-2025 models that may be installed at an incorrect angle, preventing it from properly restraining an occupant in a crash.
On the current and near-current generation, 2021-2024 models have second-row seat backs that can fail to lock during adjustment and shift freely in a crash. Some 2021-2024 vehicles distributed through Southeast Toyota were also fitted with 20-inch accessory tires carrying an insufficient load rating, which can fail under load, and the same tire load issue applies to 2022-2024 L and LE trims equipped with the Blackout Package. The 2020-2023 model years have a front lower bumper cover that can detach after minor impact and become a road hazard. On 2020 models, an engine stop-start programming error can cause the engine to stall while driving, and a separate 3.5L V6 engine control unit issue produces the same stall risk through a different fuel supply fault; 2020 vehicles also have front seats where an incorrect trim cover can block the side airbag from inflating in a crash.
Going back to the mid-2010s, the 2015 model year has an electric power steering control unit that can fail over time and leave the driver without power assist. The 2014 model year carries several seat and restraint issues: a third-row center seat belt that may not be anchored to the floor, a second-row right-hand seat that can fail to lock into its track, a front passenger airbag that may not deploy with appropriate force due to a software error in the occupant classification system, and a seat belt anchor software defect affecting the same passenger position. On 2016 models, the brake fluid level sensor can be disconnected from the wiring harness, preventing any low-fluid warning and allowing braking performance to quietly degrade. The 2017 model year has accessory roof rail cross bars whose fasteners may not be properly torqued, allowing the rails to detach at speed.
Further back, 2014-2015 models share the power steering control unit defect described above. The 2013 model year has a second-row left seat that can fail to lock in forward adjustment positions. On 2009-2013 models distributed through Southeast Toyota, the front passenger seat occupant sensor can fall out of calibration, causing airbags to deploy incorrectly or not at all. The 2008 model year has a curtain airbag roll-angle sensor that can trigger the side curtain airbags and seat belt pretensioners without a crash. The 2008-2010 model years have a floor mat entrapment risk where an unsecured mat can pin the accelerator pedal wide open and make the vehicle difficult to stop. On 2006-2010 Highlander Hybrid models, the inverter can fail and drop the vehicle into a severely limited limp-home mode. The 2004-2006 model years have a brake master cylinder where use of incompatible brake fluid causes an internal rubber seal to dry out and curl, leading to brake fluid leakage and degraded braking over time. The 2004 model year also has a center console cover that can contact the accelerator pedal rod and prevent it from returning to idle.
On the earliest production years, 2001-2002 models have a fuel tank breather hose clamp that can break in a high-speed
