NHTSA (USA)Critical
At a glance
What can fail
Water can leak into the wire harness attached to the aftermarket replacement windshield, potentially damaging the engine control module.
What the fix does
This page covers 4 recalls, 115 owner complaints, NHTSA crash-test ratings and EPA fuel economy for the 2016 Toyota Highlander.
20–28 mpg combined
8.4–11.8 L/100km
Standard Sport Utility Vehicle 4WD
Fuel economy data from fueleconomy.gov (EPA / U.S. Dept. of Energy). Annual cost based on 15,000 mi/yr at 55% city driving and current fuel prices. MPG is U.S. gallons; L/100km converted. Ranges reflect the 2 tested variants for this model year.
5/5 Overall
NHTSA 5-Star Safety Rating
For the 2016 Highlander, brake-related complaints make up the largest named category, with owners frequently describing reduced stopping ability, longer-than-expected stopping distances, and brakes that feel unresponsive or require unusually firm pedal pressure in normal highway traffic situations. The electrical system draws the next-highest complaint volume, with owners reporting a range of issues including warning lights, unexpected power losses, and various components behaving erratically. Exterior lighting rounds out the top three, with owners describing headlight and other lighting failures. A smaller cluster of steering complaints describes a steering column that can wear prematurely, leading to loose or unresponsive steering, in some cases owners report having to apply significant force to steer the vehicle. Tire wear complaints also appear, with owners describing uneven or accelerated tread wear well before expected mileage thresholds.
115
Total Complaints
14
Crash-Related
1
Fire-Related
8
With Injuries
By System
The 2016 Toyota Highlander has 4 recalls, the most serious involving certain aftermarket replacement windshields whose wire harness can allow water to enter and damage the engine control module, potentially causing the engine to stall while driving.
A separate issue affects vehicles built between late May and mid-September 2016: the brake fluid level sensor may not have been connected to the wiring harness during assembly. If brake fluid drops to a low level, the sensor cannot detect it and the dashboard will not warn the driver, meaning braking performance can degrade without any indication. Prior repair attempts did not fully resolve this issue, and it was filed in multiple jurisdictions, but the underlying problem is the same disconnected sensor.
The remaining recall is a compliance matter involving certain vehicles distributed through Southeast Toyota. The load carrying capacity label may not correctly account for the weight of dealer-installed accessories, which means the listed capacity overstates how much additional cargo the vehicle can safely carry. Overloading based on that incorrect figure raises the risk of handling problems or a crash.
At a glance
What can fail
Water can leak into the wire harness attached to the aftermarket replacement windshield, potentially damaging the engine control module.
What the fix does
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Driver Assistance
Ratings from NHTSA's New Car Assessment Program (NCAP). Based on 2 tested variants; worst-case ratings shown.
Complaints are owner-reported and reflect individual experiences, not confirmed defects. They are distinct from recalls. Data sourced from the national vehicle safety complaint database. See trending complaints →
Service centers will replace the windshield and inspect the engine control module for damage, replacing it if necessary, at no cost.
Summarized — see the official notice for exact wording, dates, and contacts.
At a glance
What can fail
The brake fluid level sensor wire harness may not be properly connected, preventing the sensor from detecting low brake fluid levels.
What the fix does
Dealers will inspect the sensor connection and reconnect the wire harness to the sensor as needed, at no cost to you.
Summarized — see the official notice for exact wording, dates, and contacts.
At a glance
What can fail
The brake fluid level sensor wire may not be connected at the factory. If brake fluid drops below safe levels without triggering a warning light, braking performance could be affected.
What the fix does
Dealers will inspect the brake fluid level sensor connection and connect it if needed.
Summarized — see the official notice for exact wording, dates, and contacts.
At a glance
What can fail
The weight capacity label may show incorrect added weight from installed accessories, causing the vehicle to not meet federal tire and rim safety standards.
What the fix does
A corrected label will be provided and placed over the inaccurate one at no cost.
Summarized — see the official notice for exact wording, dates, and contacts.
