2025 Toyota Grand highlander

The vehicle exhibits abnormal fuel system behavior. When the vehicle reaches a low fuel condition (approximately 40–50 miles to empty), the fuel tank only accepts about 12 gallons, even though the listed tank capacity is 17.2 gallons. After refueling, the fuel gauge displays FULL and the “Distance to Empty” reading jumps to over 360 miles, which is inconsistent with the amount of fuel added. A Toyota dealer documented this behavior on a repair order, stating that the tank accepted only 12 gallons from a low fuel condition and immediately displayed a range of 363 miles. A second repair order states that the fuel system was inspected and that the tank supposedly has a “3–5 gallon reserve,” but no technical documentation was provided to support this claim. Toyota’s customer support later provided a written response stating only that mathematically 3–5 gallons must have been in the tank, without offering any engineering explanation for why the gauge reads FULL or why the vehicle reports an inflated driving range after adding only 12 gallons. The dealer also provided documentation explaining the issue using online forums and social media posts rather than Toyota engineering documentation. Safety concern: Because the gauge displays FULL and the vehicle reports a high range when the tank has not actually been filled to capacity, the vehicle may be operating with significantly less fuel than indicated. This creates a risk of unexpected fuel starvation, hybrid system shutdown, and loss of propulsion if the vehicle runs out of fuel while the driver believes adequate range remains. Supporting documents include dealer repair orders, Toyota’s written response, a dealer explanatory response, and confirmation that the issue was escalated internally.

I experienced a serious safety incident involving my 2025 Toyota Grand Highlander with approximately 14,000 miles. While driving on a straight interstate highway at approximately 70 mph, surrounded by other vehicles, the steering wheel suddenly made two to three sharp, forceful jerking movements to the left. Afterward, the steering wheel remained approximately 20 degrees off-center to the left. All lane departure assistance sensors were active during the incident. This unexpected steering behavior created a significant safety hazard. At highway speed, I could have lost control of the vehicle, departed my lane, or collided with surrounding traffic. I was able to reach my destination, but the steering wheel remained crooked. Immediately afterward, I took the vehicle to an authorized Toyota dealership for inspection and repair. The technician reported that the left rear wheel was significantly out of alignment and that the left rear alignment eccentric lock nut was loose. According to the technician, this caused excessive wear on the inside tread of the left rear tire. The dealership also performed a vehicle health check to identify any system faults. My vehicle has always been serviced by authorized Toyota dealerships. At the last service appointment, at approximately 10,000 miles, no related problems were identified. The technician confirmed that no alignment-related work had been performed during that visit. The vehicle had no previous similar issues. I am concerned that the loose alignment eccentric lock nut and resulting severe misalignment may indicate a mechanical defect that could compromise vehicle stability and steering safety. The sudden steering movements at highway speed presented a serious risk to me, my passengers, and other motorists. I respectfully request that NHTSA investigate this incident and determine whether a safety defect exists in the 2025 Toyota Grand Highlander involving the rear suspension alignment component, eccentric locking, sensors.

On 9/26 at about 10:15am, my husband and I were fully stopped at a red light with his foot on the brake. Without him touching the gas pedal, the car suddenly surged forward as if it had been accelerated. It stopped for a moment, then surged forward again. Because he was holding the brake, the car didn’t move much, but each surge caused a hard jolt that felt like being rear-ended. No other vehicle hit us.

While driving in neighborhood at around 25 mph car started to sputter and lose power. Started flashing on display regarding ADAS which all disengaged then hybrid system failure message displayed. Stopped car, called dealership and asked if safe to drive. They said it was ok and set appointment for next morning, they contacted Toyota and confirmed it needed a new transmission. Gave me a rental and said car was do not drive. Said transmission backordered under warranty.

Driving in city traffic during morning rush hour, sitting at traffic light, when display lights up indicating “Hybrid Malfunction” and “take vehicle to dealer”. Leaving traffic light, the vehicle at first does not move after pressing accelerator, then slowly engages and thugs along. Pull over on closest side street and turn off vehicle, hoping just a fluke. Restart vehicle and drive a few yards. Stop and attempt to resume driving. This time the vehicle does not react at all, neither in drive or reverse. I was able to put in neutral and coast to nearby parking spot so not to block traffic. Had vehicle towed to my hometown Toyota dealer. Upon inspection, they notified me that a small object, probably a rock, had punctured the radiator , that it was not covered under the warranty, and would cost $2500 to fix. The suddenness and abrupt fashion this incident occurred could certainly have resulted in an accident or left be stranded in an unsafe area.

Engine temperature overheated during long idle on an out of town event. The vehicle put in park and engine running in idle with AC running. Vehicle coolant temp reach high mark in the red area. Vehicle temp alarm gave a warning to shutdown. I estimated the car idle time 40 min due to traffic accident ahead. The incident occurred on 9/11/26. The car was taken to dealer 9/17/26 for checkup/diagnose the issue. Dealer stated, they could not duplicate the issue. But they did my find the vehicle computer log, the engine registered high temp.

The contact owned a 2025 Toyota Grand Highlander. The contact stated that while driving at an undisclosed speed, the check engine warning light illuminated. The vehicle was taken to the dealer, where it was diagnosed with radiator failure. The contact was informed that there was a hole in the radiator. The contact was informed that the radiator needed to be replaced. The vehicle was repaired. The manufacturer was contacted by phone and made aware of the failure. The failure mileage was approximately 15,000.

A piece of road debris/rock struck the radiator/heat exchangers in my 2025 Toyota Grand Highlander Hybrid that immediately damaged the radiator/heat exchangers to result in coolant leakage and sudden loss of propulsion and terminated the engine from moving and required a tow to a Toyota dealer and thus a replacement of the heat exchanger/radiator. It came apparent from their experience that the design of the front-end grill has large, open apertures and no protective screen between the grill and the vehicle’s heat exchangers. Had to file an insurance claim under comprehensive coverage that required me paying a deductible for repairs and NOW stress in future driving experiences.

Our 2025 Toyota Grand Highlander Platinum repeatedly produces a strong gasoline odor and visibly observable vapor under hot-weather/hot-soak conditions. The condition has been observed by dealership personnel. There is footage from us and the dealership. The manufacturer has characterized the condition as normal, but has not provided a technical explanation identifying the source of the vapor or documentation establishing that visible gasoline vapor is within design/safety specifications. I am reporting this because I am concerned that waiting until an injury, fire, or other serious incident occurs before addressing the condition is inappropriate. I am asking NHTSA to determine whether this represents a safety-related defect or a broader safety issue affecting other Toyota vehicles. I am unable to upload the video, but I am willing to provide it by other means.

The contact owns a 2025 Toyota Grand Highlander. The contact stated that while driving 70 MPH, the air conditioner failed to operate. There was no warning light illuminated. The vehicle was taken to the dealer, where it was diagnosed and determined that the condenser had failed and needed to be replaced. The dealer informed the contact that the front grille had large open apertures and no protective screen between the grille or the heat exchangers. The vehicle was repaired. The contact stated that the failure was associated with NHTSA Investigation: DP26006 (Engine and Engine Cooling). The manufacturer was made aware of the failure by telephone, and a case was opened. The failure mileage was approximately 15,450.

I am experiencing a strong gasoline odor & what appear to be gas vapors coming from the gas cap/filler area of my vehicle. A daily problem. Fumes are consistently present & enter the cabin, when the air conditioning is not on recirculation mode or when doors are opened. I can see and smell it when stopped & idling & I can visually see it when driving. Toyota has already performed multiple inspections & safety checks but has been unable to identify the source. A vehicle health check found no diagnostic trouble codes. The EVAP system was pressure tested & passed w/ no leaks found. Fuel lines, fittings, injectors & the high-pressure fuel pump were also inspected & all reportedly passed. The inability to identify the source does not mean the condition does not exist—it demonstrates that the current testing has not identified the source. I should not be expected to continue transporting my family in a vehicle w/ an ongoing gas vapor concern simply because standard diagnostic testing has not located the problem. My greatest fear is that an unidentified source of gas vapors could create a serious fire or explosion hazard. Gas vapors are highly volatile & when present in sufficient concentrations & exposed to an ignition source, can ignite. I continue to smell gasoline & detect what appear to be vapors around & inside the vehicle every day, I am afraid to drive it & constantly worry about the possibility of a fire or explosion while my children are inside. Breathing in these fumes are extremely toxic. My greatest concern is for my three children. Two are under the age of [XXX] & cannot communicate whether they are experiencing headaches, dizziness, nausea, respiratory irritation, or other symptoms. My [XXX] rides in the third row, closest to the rear area where I am detecting these vapors. I purchased this vehicle to safely transport my children. Instead, I no longer feel safe transporting my family in it. This is an ongoing, unresolved safety concern. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

The contact owns a 2025 Toyota Grand Highlander. The contact stated that while driving approximately 35 MPH, another vehicle struck a rock, and the rock went through the front grille of the vehicle and punctured the inverter radiator, causing a coolant leak and a loss of motive power. The message "Hybrid System Malfunction" was displayed following the loss of motive power. The vehicle was towed to a dealer, where it was diagnosed and determined that the inverter radiator had sustained a puncture and needed to be replaced. The vehicle was repaired. The contact associated the failure with NHTSA Action Number: DP26006 (Engine and Engine Cooling). The failure mileage was approximately 14,300.

The contact owns a 2025 Toyota Grand Highlander. The contact stated that while driving 60 MPH on the highway with a three-year-old child in the vehicle, the message "Pull Over Immediately and Shut Off the Vehicle" was displayed. The contact was able to pull over to the side of the road and waited for a tow truck in hot weather. The vehicle was towed to a dealer, where it was diagnosed and determined that the radiator was punctured by a rock that had gone through the front grille and caused a coolant leak. The dealer determined that the radiator needed to be replaced. The vehicle was scheduled for the repair. The contact informed the dealer that the failure was a common issue associated with NHTSA Action Number: DP26006 (Engine and Engine Cooling); however, the dealer informed the contact that the manufacturer was not aware of the issue. The failure mileage was approximately 12,200.

Load cabin wind noise. Service said it was the luggage bars on the roof. I removed the bars and the noise was the same. Came back to the shop on August 22, 2026 they looked and said the panoramic seal was lifting and leaking. Before buying the car we were told the prior issue with panoramic sunroofs leaking had been resolved. In addition the plastic handle that controls the middle seat broke off after using it three times.

I have noticed on several separate occasions a strong gas odor coming from my 2025 Toyota Grand Highlander after I have completed a drive. This has been intermittent, however, yesterday on XXX, the gasoline odor was so strong after I parked my vehicle in my garage, that it quickly filled the garage with an overwhelming odor. My son urgently came to get me when he stepped into the garage and realized how strong the fumes were. We had to open the garage to air it out. I called the Larry Miller Peoria Toyota dealership immediately and had my vehicle inspected the following day on XXX. I was informed by the service advisor that Toyota receives numerous complaints daily about this very issue with the newer model Highlanders, Grand Highlanders, Tacomas, and 4Runners. I insisted that my vehicle be inspected. The report stated that they were unable to duplicate the condition. The report states that no leaks were found with the evap system. The report also states that whe outside temps are extremely high, fuel inside the tank expands and creates additional vapor. I was assured by the service team that the fuel tank is operating correctly, despite the overwhelming fuel vapors that are intermittently emitted. I have lived in [XXX] my entire life and I have never encountered this issue with any vehicle that I have owned. These fumes are toxic and I am very concerned about my family being exposed and our safety/wellbeing. I have installed a carbon monoxide monitor in my garage. I have also filed a formal complaint at the Corporate level within Toyota and am awaiting a response. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

I continuously have issues accelerating from stop in my max hybrid. the issue is particularly worse when it is warm out. I press the gas and the RPMs drop really low and I barely move through the intersection for a few seconds. Once it finally registers after a number of seconds, the RPMs rev up over 4000. It is very dangerous trying to proceed through an intersection and the car basically stalls when I press the gas. It especially concerns me that I have my child in the car with me and I worry when it is going to act up. I know others have experienced this issue and there was a TSB for 2024 models that had this issue. I have a 2025 and experience this issue. I have had toyota look at it and they said they cant do the TSB since it's bot for my VIN. A solution needs to be found for the the safety of myself and others.

I have over 30k miles on my car. Over the period that I’ve owned it there have been a few, roughly 6, occasions where I’m trying to change lanes from a stop into quick traffic and my car lags 1-3 seconds in response to me pressing the gas petal. It happens infrequently and is not the normal response. Other times the car responds as one would expect.

on 8/13/2026, I was driving alone on West I-80 right before Park City, Ut; I heard a loud pop and my panoramic sunroof exploded which was really scary. I was not using my sunroof at all, so the cover protected everything on the inside. At first I thought it was a flat tire, but no warning messages came onto the control panel. There were not immediate safety issues, so I was able to get to a Toyota Dealership to have it repaired. I did not hear any gravel or road debris flip up onto my sunroof, nor did I hear any under my tires when driving. My vehicle was inspected by a service technician at the Toyota Dealership and he just said it was probably caused by an outside influence.

My wife was driving and a small rock passed through the front grill puncturing the radiator and causing her check engine light to come on. Within 5 minutes the coolant leaked out and the car was undrivable. We took it to Bredemann Toyota in Park Ridge who replaced it.

Rodent damage to plant based wiring to Engine Harness A and valve vacuum hose. Cost $1700 and 2 repairs.