2024 Toyota Grand highlander

On XXX, at about 2:00 PM we were driving south on I95 somewhere in [XXX] when we heard a very loud noise. Thinking it was a rock hitting the windshield we looked but could see no cracks or chips so we kept driving on our trip to [XXX]. The next day it was windy and we thought it was unusually noisy inside the vehicle but we just thought it was the wind. After driving around in [XXX] we said it was unusually noisy inside so I said I would stand on the door sill to look at the roof and that’s when I saw the hole in the sunroof. That night, Sunday, XXX, I called our insurance company to report the damage. They said that an adjuster would contact us on Monday. Meanwhile I started to “Google” issues with sunroofs and there I found out about imploding glass sunroofs. On Monday, XXX, I went to the Toyota service in [XXX].and had them look at the damaged sunroof. The service advisor mentioned he had never seen this damage. He said they could replace it but would have ordered parts which could take a couple days. I said to go ahead as we were only here until Saturday. That day, Monday XXX I called the insurance company to update them. I also stopped at the Toyota dealer to talk with them. I mentioned the “Google” reports about sunroof issues. The advisor said there were no recalls or anything from Toyota on this. He did say that an insurance adjuster had contacted him and said they were very busy but would try to get there to look at the vehicle on Tuesday. We are thankful we did not have the sunroof cover open as we would have had glass all over inside the vehicle. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

Incident occurred on XXX at 9:46AM PST, [XXX]. When applying brakes normally to come to a gradual stop behind another vehicle stopped at a stop sign on a slight decline, PCS collision warning lights enabled and vehicle lurched forward while my foot was on brake. This is not to be confused with automatic braking behavior as front collision warning lights in driver information center flashed red. Rather, vehicle lurched forward as if accelerating once within feet of vehicle in front. Then, vehicle rocked front to back multiple times with my foot still on the brake, as if Drive and Reverse was being quickly and intermittently engaged back and forth about 1 second apart. Had my foot not been firmly on the brake, the vehicle felt like it would travel forward and then back (colliding with vehicle in front and in back) without driver inputs.   While car continued to lurch forward and then back, I shifted transmission into Park then back in Drive, and behavior stopped.  There was a loud clunk as the car engaged in Drive.  This has occurred 3 times over the past 2.5 years. What is even more curious, is that this occurred all 3 times at the same stop sign, which is at a slight decline. This leads me to deduce that somehow the angle of decline or other specific condition at this stop sign is somehow contributing or confusing vehicle systems, as bizarre as this sounds. AC was on during at least one preceding event but not during yesterday's event. Others have observed similar events on on-line forums, but I don't know if they have reported this given how infrequently it occurs. Vehicle has 28000+ miles, and I stop at this exact location at least 3 times per week, with behavior observed only 3 times. Statistically, it seems probable that there must be some element (angle of decline?) at this location that somehow confuses vehicle systems, triggering this dangerous unintended acceleration and reversing behavior. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

Dear NHTSA Vehicle Safety Team, I am writing to report a serious steering system issue to my 2024 Toyota Grand Highlander Hybrid and to request that NHTSA review this incident for potential safety concerns affecting other owners of the same vehicle model. Vehicle Information - Make and Model: 2024 Toyota Grand Highlander Hybrid - VIN: [XXX] - Mileage at the time of the issue: Approximately 66,000 miles - Component involved: Steering rack/rack-and-pinion assembly Sequence of Events 1. Steering System Failure At 65,000 miles, i started having minor issues with the steering system, but was driving fine. At 85,000 miles i had the vehicle examined at Toyota, (cause steering rack just stuck) informed me the steering rack needed to be replaced, (repair cost 3300$). 2. Vehicle Maintenance History I have maintained my vehicle in a timely manner. at always 5000 miles, during my communication with Toyota's Brand Engagement Center, they acknowledged that my maintenance history was satisfactory. 3. Previous Accident and Service Documentation I contacted Toyota's Brand Engagement Center and requested goodwill assistance with the repair because of the nature of the failure, the vehicle's mileage, and its maintenance history. Toyota ultimately declined to participate in the repair, citing the prior accident. I also requested a written explanation , but denied my request for goodwill assistance, citing the vehicle's involvement in an accident, minor rear end to my rear door and bumper, not my fault. My service documentation dated XXX, (2 months prior the accident) contains a reference to the rack-and-pinion boot and a listed amount of $54.26, this service entry and the eventual steering rack failure to be properly examined. I am not claiming that the accident or the rack-and-pinion boot necessarily caused the failure. I just found out that my model vehicle had a steering wheel recall but 2026 model, maybe has the same issues. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

Has a VERY strong gas smell and fumes near gas tank after car has been idling.

2024 Toyota Grand Highlander Hybrid AWD. Vehicle exhibits a severe metallic "clunk" or "boom" noise and impact from the undercarriage specifically when reversing under moderate to firm acceleration. This is a recurring issue reported by numerous owners of this model, related to harsh powertrain engagement and movement when changing direction under load. This issue is NOT related to wheel rotation, brakes, or CV axles. The vehicle has approximately 70,000 miles, has been driven strictly on paved roads with no towing or off-road use, and has no active warning lights. The sudden mechanical shock while engaging reverse poses a potential safety and reliability concern regarding drivetrain components.

The air conditioning system on my 2024 Grand Highlander failed due to a punctured AC condenser caused by road debris passing through the front grille during normal driving. The front fascia has large open apertures with no protective mesh or screening, leaving the condenser, radiator, and other heat exchangers directly exposed to rocks and debris. The condenser face shows multiple debris strikes, with one impact puncturing the core and causing complete refrigerant loss and AC failure at approximately 62,000 miles. The vehicle worked normally when parked and the AC was completely dead one week later due to the slow refrigerant leak from the puncture. Diagnosis was performed by [XXX] Toyota in [XXX], which confirmed the puncture was caused by road debris. The repair is not covered under warranty or my extended service contract because it is classified as outside damage, leaving owners to pay out of pocket for a design vulnerability. This is the same failure mode described in open ODI Defect Petition No. XXX covering 2024-2026 Grand Highlander vehicles. The same unprotected grille openings expose the engine radiator, meaning the identical debris path can puncture the radiator and cause coolant loss, engine overheating, and sudden loss of propulsion in traffic. The grille design leaves critical cooling components unreasonably vulnerable to everyday road debris. Photos of the punctured condenser and the dealer's written diagnosis are available. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

I own a 2024 Toyota Grand Highlander Hybrid MAX Platinum, purchased brand new in February 2024 and now with approximately 30,400 miles. Since the first few weeks, the vehicle has had an ongoing fuel tank/range issue. The fuel tank is rated at approximately 17 gallons, but the gas pump consistently shuts off after only 10–12 gallons, even when the vehicle indicates 0 miles to empty. It accepts approximately the same amount whether I refuel with 80, 20, or 0 miles remaining. After filling, the vehicle reports the tank as full and but generally shows only 270–290 miles of estimated range. The actual miles driven before requiring fill up is 230-250 miles. Toyota issued T-SB-0060-25 (Low Fuel Warning Light Logic Enhancement), which a Toyota dealer reluctantly performed on my vehicle. It initially improved the displayed range by only about 10 miles, but did not resolve the problem, and the condition is now worsening. The dealer solution was to tell me I can drive another 60-100 miles past empty but I do not believe that is a reasonable or safe workaround. This is because the driver cannot reliably determine the remaining usable fuel or how far the vehicle can safely travel. The condition remains unresolved and is a known issue with other Toyota Grand Highlander Hybrid Max owners.

2024 Toyota Grand Highlander XLE FWD. At approximately 38,000 miles I began hearing a roaring/humming noise that varied with vehicle speed. The condition initially progressed slowly but then became much worse within several days. At 41,510 miles a Toyota dealer diagnosed and replaced the right rear hub/wheel bearing assembly. I was advised that the failed bearing was nearly seized when removed. After replacement the noise was reduced but remained present. The dealer was uncertain whether another bearing was failing and initially believed the remaining noise could be tire noise, advising me to monitor it. The noise again deteriorated rapidly and became severe enough that I considered the vehicle unsafe to drive. At 42,223 miles the same dealer diagnosed and replaced the left rear hub/wheel bearing assembly. The noise disappeared after replacement. Both rear wheel bearings therefore failed at approximately 40,000–42,000 miles within about 700 miles of each other. The vehicle has no known accident or suspension damage and the dealer identified no other condition causing the failures. I am concerned that rapid deterioration or seizure of a wheel bearing while driving could result in loss of vehicle control.

400lb animal strike, no warning lamps on, sensors was replaced from Toyota Ashland KY last year. My wife and 14 year old daughter was in the front seats. Traveling speeds was 55mph zone was traveling approx 45mph.

If my car has been sitting for a while, especially in the heat, and occasionally at random times, when you get in the car and press the gas, the car will not move. This happened twice where I was almost put in a very bad accident. There is a very hard intersection near my son’s school. I have to take a left hand turn- and you have to be quick because there is no light. I turned left and my car would not go- I was stuck in oncoming traffic and the car would not move whatsoever. It was very dangerous and very scary. This has happened where it almost caused a very bad accident becuase the gas pedal would not move the car. The dealership couldn’t replicate and said it wasn’t an issue. But it is continuing to happen, and it is very dangerous. Maybe it has something to do with the battery getting hot and somehow power doesn’t get to the gas/engine e

When ambient temperature are over 90 the vehicle will lose power during acceleration. This happens typically in the speed range of 20-35mph. The vehicle’s rpm will spike high but lose the ability to increase speed or shift gears. This occurs 40-50% of the time when over 90 degrees. On several occasions we were forced to abandon merging onto the highway because the vehicle wasn’t safely able to accelerate to match the speed of vehicles on the highway. We reported this issue to our local Toyota dealer September 2025. After reviewing the vehicle they said nothing was wrong. We had them drive it longer and they agreed the vehicle had these issues. The dealership spoke with Toyota and they confirmed there was an issue for our vehicle and a lot of others and they had no fix for it. That was September 30, 2025; Toyota Brand Engagement Center Reference # 250923001413. There has been no communication from Toyota or our dealer since then. The safety issue with the vehicle is a major concern in operation of the vehicle and with the hot climate we live in, is putting our occupants and others on the road at risk and we feel Toyota needs to be held accountable for finding the issue(s) and correcting them.

At 5:16 pm, CST. I was stopped at a stop sign headed west on a 25 mph road crossing a 30 mph road (that does not have a stop sign) in Illinois. After waiting for a an appropriate gap in traffic, I attempted to accelerate though the interesting. I released the brake pedal and attempted to accelerate. The vehicle barely accelerated. The engine seemed to minimally climb in RPM and only accelerated minimally out into the cross road. This lasted approximately 1-2 seconds. AT this point I was fully into the first lane of traffic. I then fully depressed the accelerator to try to get the vehicle to respond and after approximately a 0.5 to 1.0 second delay the engine fully responded and I was able to accelerate out of the oncoming cross traffic. This is by no-means the first time this behavior has happened with this vehicle but it is the first time I'm reporting it to the NHTSA.

Horrible gas smell on the interior and exterier of vehicle after fueling up.

I currently own a 2024 Toyota Grand Highlander with the 2.4L turbo engine, which I purchased in July 2023. I have been experiencing a strong gasoline/fuel smell coming from the vehicle. I took the vehicle to Fox Toyota in El Paso for inspection. According to the dealership, the smell was caused by the gasoline I was using and they stated that the fuel contained too much ethanol. However, the gasoline smell was strong enough to be concerning, and I am not comfortable simply assuming that the fuel is the cause without further inspection. At this time, I have not been given a specific diagnosis identifying a failed component or confirming that a particular fuel-system component is malfunctioning. The vehicle is available for further inspection if requested. The strong gasoline odor raises a safety concern because the presence of fuel vapors could potentially indicate a fuel leak or another problem with the fuel system, creating a possible fire hazard. The problem was reported to and inspected by Fox Toyota in El Paso, but the dealership attributed the odor to the ethanol content of the fuel rather than identifying a defective component. I have not had the vehicle inspected by the manufacturer or any other independent facility at this time. I have not observed any warning lights or warning messages associated with the problem. The primary symptom has been the strong gasoline smell. The vehicle has the 2.4L turbo engine. I would like to know if other 2024 Grand Highlander 2.4L turbo owners have experienced the same issue and, if so, what the actual cause was and how it was resolved.

The vehicle’s A/C suddenly began blowing hot air. We took it in for diagnosis. The technician asked if the vehicle had been in an accident, if the front had hit anything, or if we had noticed hitting a rock or other object. We answered no to all questions. The technician stated they have seen this issue numerous times, where road debris passes through the large openings in the factory front grille and damages the A/C condenser. The condenser was found to have localized physical damage of approximately 1 cm in size, consistent with an impact from a rock or other road debris. The impact cracked/punctured the condenser, causing refrigerant to leak from the sealed A/C system and the A/C system to stop functioning. The condenser requires replacement. We researched this issue and found other Toyota owners reporting similar condenser damage from road debris entering through the front grille. We understand that road debris and normal wear can occur, but our concern is that the large factory grille openings allow ordinary roadway debris to directly reach the condenser, with inadequate shielding or protection. A $1,700 repair for a condenser that can be damaged by ordinary road debris entering through the factory grille openings is a significant and potentially recurring expense. Consumers should not reasonably expect to repeatedly incur this level of repair cost because a critical component is inadequately protected from normal roadway conditions, particularly when the vehicle is also covered by an extended warranty that does not cover the repair. This issue also appears relevant to NHTSA Petition DP26006. We ask NHTSA to investigate whether this design leaves the condenser unnecessarily vulnerable to normal roadway debris and whether other vehicles are experiencing the same problem. While the immediate result is loss of A/C, we are concerned about the broader safety implications of critical vehicle components being vulnerable to damage under normal driving conditions.

A/C condenser damaged and broken caused by open grill design.

Multiple times a week in the summer my car will hesitate to go once I have stopped at a stop sign/busy four way intersection. When I push the gas the car doesn’t respond and hesitates for a long while before I can get the car to start moving again. The car will roll into the intersection after I take my foot off the break to go and it won’t do anything. It is terrifying and confuses other drivers around me thinking that I am letting them go. This has happened upwards of 20 times since I have had the car. It happens only on hot days when the external temperature is above 80 or so degrees and happens when car is freshly started. It reliably happens when I go up a pretty small hill by my house about 1 minute after starting the car (even when it is coming from being parked in my garage). Joseph Toyota on Colerain in Cincinnati has not been able to reproduce the issue. I drive with two children in the car and it is so scary when it happens because I have almost been hit with them in the car many times now.

My coolant evaporates . I think a tick hit through grill and damaged the heat exchanger. I have to fill the coolant monthly

Damage occurred to the front air conditioning system because a rock flew through the open grill area. This punctured the system causing a couple thousand dollar repair, not under warranty. The car was nearly brand new at the time. The grill area is a problem, it's a bad design.

Sometimes, when trying to accelerate in certain situations, the vehicle accelerator pedal will not respond or the engine stutters and won't immediately respond to input and the vehicle seems to stall. This has been scary several times in traffic. The vehicle originally would throw an engine code on the dash about system failure and was taken into the dealer after several of these incidents and a software updates was performed, but it still happens randomly although now with no code.