2021 Toyota Highlander

While driving and applying the brakes to come to a complete stop at low speed (approximately 5–15 mph), the vehicle intermittently loses brake responsiveness for a brief moment during the transition from regenerative braking to hydraulic (friction) braking. This causes the vehicle to lurch forward unexpectedly before the brakes fully re-engage. The issue is intermittent and unpredictable, occurring most often when coming to a stop at slow speed, which makes it difficult to anticipate and compensate for. This has happened more than a few times now, most latest, On XXX, this occurred while approaching a stop at traffic light and it felt that the vehicle nearly made contact with the vehicle ahead of me. I brought the vehicle to Elgin Toyota in [XXX] , in 2025 to report this issue. The service department test drove the vehicle but was unable to reproduce the symptom and did not perform any repair. I have since learned that Toyota issued Technical Service Bulletin T-SB-0059-23, "Hybrid Regenerative Brake Transition Feeling Improvement," dated XXX, which describes this exact symptom in 2020–2022 Toyota Highlander and Highlander Hybrid vehicles. I am filing this report because I believe this is a safety-related braking defect, particularly at low-speed stops, that creates a real risk of a rear-end collision. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

I had the dealer perform the repair described in Toyota Technical Service Bulletin T-SB-0059-23 (Hybrid Regenerative Brake Transition Feeling Improvement), which reprograms the brake actuator control module. Following this repair, the vehicle continues to exhibit the same lurching behavior at the same frequency as before the update. The TSB did not resolve the underlying condition. This is a safety concern because the unpredictable brake transition affects the driver’s ability to judge stopping distance and vehicle behavior in real time, particularly in traffic or on downgrades. The vehicle now has over 36,000 miles, placing it outside Toyota’s Basic Warranty; however, this is a safety issue that should be addressed by a recall. I am aware of numerous other Highlander Hybrid and Sienna Hybrid owners reporting the same defect, including reports that the same TSB reflash failed to resolve the issue for them as well.

When applying the brakes when slowing down fro a traffic light or in traffic, the brkaes suddely stop workign for a few sseconds at a speed of 5-10 mph, causing car to lurch forward before the brakes reengage. This has existed for a couple of year but has gotten worse in thelast 6 month.s The risk is that the lurch occurs prior ot the full stop ,potentilly causing the car to run into the car directly in ftont of our car. Toyota is aware of the problem and issued a technical sevce bulletinT-SB -0059-23 whichidentified this and a software update helps in resolving the issue. The bulletin however states the cost needs ot be paid by th cusotmer if it is out of warrnaty. This does not makes snse as it is a potetnail safety issue that coudl casue a collisiion and wodul seem to rise to the level of a recall. There are many refermces to the issue on social media. It seems Toyota should be rqeuired to make this a recall item at no cost to the customer.

•The transmission malfunctioned and developed an abnormal internal noise at approximately 67,000 miles, which is an unexpected failure at low mileage. The vehicle had been properly maintained and had no prior mechanical issues. Atlanta Toyota inspected the vehicle and confirmed the transmission had failed and required full replacement. The dealer also stated that as a result of the transmission failure, other related components showed excessive and abnormal wear. A second independent service center inspected the vehicle and confirmed the same diagnosis. The vehicle is available for inspection upon request. • This unexpected transmission failure created a serious safety risk due to the possibility of sudden loss of power, inability to accelerate, or complete transmission failure while driving. I rely on this vehicle daily to transport my child to school and to commute to work. A sudden failure while in traffic could result in becoming stranded or involved in a collision. • The vehicle was inspected by an authorized Toyota dealer and an independent service center. Both stated that the failure was unusual given the low mileage and normal use of the vehicle. • There were no warning lights, messages, or diagnostic trouble codes prior to the failure and afterward. The only symptom was an abnormal internal noise from the transmission, which began suddenly at approximately 66,000 miles. • The vehicle has received regular maintenance and is used for normal daily driving. There was no abuse, heavy towing, or unusual use that would explain a transmission failure at this mileage.

Under braking conditions, typically at higher speeds or while going downhill, vehicle will lurch or accelerate momentarily before braking again. This has caught 3 drivers in our family off-guard as it is intermittent and sudden. This is unpredictable and causes the braking distance to vary. We are working to reproduce it. The dealership has not tried to recreate the issue but has told us there is a software update that will fix the issue, it is not covered under any safety recall or safety campaign by Toyota.

There is a Technical Service Bulletin (TSB-0059-23) issued for 2020-2022 Toyota Highlander Hybrid models addressing a braking issue. It happens every day. There are a lot of issues Some drivers reported a momentary transition from regenerative braking to hydraulic braking, particularly when driving downhill or turning with light brake pedal application. Toyota has provided a software update for the brake actuator control module to improve brake feel. If you own one of these models and are experiencing this issue, you can visit a Toyota dealership and request this specific TSB repair. Addendum: There is no charge for this fix if your vehicle is within the warranty period. The repair procedure under Toyota’s Technical Service Bulletin (TSB-0059-23) is covered by Toyota’s warranty, meaning the brake actuator control module reprogramming is performed at no cost to the owner.

I own a 2021 Toyota Highlander Hybrid. The vehicle exhibits a dangerous braking surge defect. When braking during cornering or in stop-and-go traffic, the vehicle randomly surges forward even though the brake pedal is depressed. This creates a serious safety hazard and increases the risk of collision. On multiple occasions, this defect has nearly caused an accident. The last time it happened we were driving in stop and go traffic and the vehicle surged forward while depressing the brakes and the engine died leaving a red triangle on the dash. Toyota has acknowledged this condition through Technical Service Bulletin T-SB-0059-23, which applies to my vehicle. The bulletin involves reprogramming the brake actuator assembly control module to address the braking transition between regenerative and hydraulic braking. Despite this, Toyota has refused to apply hybrid system warranty coverage, misclassifying the defect as a conventional brake issue. My vehicle is available for an inspection. I contacted Toyota corporate, who initially responded but failed to provide follow-up or resolution. The defect persists after the bulletin was applied. Toyota’s refusal to cover the repair under the hybrid warranty leaves me with an unresolved safety defect. This complaint is intended to document the ongoing safety risk and Toyota’s failure to provide adequate remedy under warranty. I request NHTSA investigate this issue as a systemic safety defect affecting 2020–2022 Highlander Hybrid models.

I am reporting a serious safety defect involving the rear brake system of my 2021 Toyota Highlander, purchased from Penn Toyota (Glen Cove, NY). The dealership represented the vehicle as “Toyota Certified” and indicated that it passed all safety inspections. On November 15, 2025, I discovered that the rear brake rotors and pads were in extremely unsafe condition, showing severe corrosion, deep pitting, uneven pad wear, and structural deterioration. This damage clearly developed over a long period of time and indicates that the vehicle could not have passed a legitimate safety inspection at the time of sale. The rear brakes had to be replaced immediately to prevent potential brake failure. After replacing the rear rotors and pads, the vehicle passed the New York State Inspection on the same day, proving that the previous brake condition was unsafe and improperly inspected. This raises concerns of: Brake safety failure Improper or falsified dealership inspection Risk of reduced stopping power Potential loss of vehicle control I am submitting photos, the repair invoice, and the inspection result that confirmed the brakes were unsafe prior to repair.