2015 Toyota Highlander

I have a 2015 Toyota Highlander XLE. Last winter I began noticing a burning smell which I believed to be electrical inside the vehicle. I was able to determine it was the driver seat heater and the burning smell continued even with the toggle switch turned off. I stopped at a local Toyota dealership, Koch Toyota, who refused to show me which plug under the seat to unplug to disconnect power. They tried to insist that I drop the car off and let them check it. Due to past negative experiences with that Toyota dealership I refused. I was able to speak to my own mechanic who instructed me to remove the fuse for the driver's seat heater which I did and the smell stopped however the seat heater is not functioning now. Upon recent research online it appears this is a common problem especially in 2015 Toyota Highlanders. I found a couple other owners of the xle models on a website called Toyota Nation who experienced similar problems where their vehicles actually caught fire and melted the center consoles after the burning smell was misdiagnosed. I believe this is a huge safety concern and have recently filed a report with Toyota Corporate in hopes to get the issue rectified. There were no warning messages or lights that came on to advise that there was an issue.

My Highlander had a strange burning smell and we couldn’t find where it was coming from. We took it to a shop where they checked everything over and suggested that the smell was our brakes. They lubricated the brakes and replaced my tires and struts. When I went to pick up the vehicle I still noticed the strange smell, and I had the mechanic come out and check. He suggested that it was the leather conditioner that our detailer had used. I left and headed for home and in about 5 miles the control for the drivers heated seat started smoking and about 30 seconds later the plastic around the control began to melt and flames were coming out of the area next to the control. I was able to use a fire extinguisher to put the fire out. All of the heated seat components were original and we haven’t had any work done to it. The obvious safety concern here would be fire in the cabin of the vehicle while in motion. The fire and sheriffs departments showed up to the scene and the incident report was filed. The vehicle was towed to a shop where we are awaiting insurance adjuster to look at it. There were not any warning lights or signals of any kind; only the smoke very shortly before the visible flames.

CAR GOING IN FOR THE SECOND TIME TO REPLACE THE ELECTRICAL SEAT ADJUSTMENT PANEL AND THE OTHER COMPONENTS NEEDED TO KEEP IT HELD IN PLACE. THE PLASTIC CLIPS ON THE PARTS JUST DO NOT APPEAR TO BE SUFFICIENT TO KEEP THE PANEL IN PLACE. CAR HAS JUST UNDER 33K MILES. THE PANEL IS RARELY USED AND IT APPEARS THAT JUST THE ENTRY AND EXIT FROM THE VEHICLE APPEARS TO BE CAUSING ENOUGH MOVEMENT FOR THE PARTS TO WEAR OUT.