2021 Toyota Highlander

The contact owns a 2021 Toyota Highlander. The contact stated that while driving on the highway at 65 MPH, the front bumper became detached. There was no warning light illuminated. The contact pulled over and zip-tied the bumper to the frame of the vehicle. The vehicle was not repaired. The contact referenced NHTSA Campaign Number: 23V720000 (STRUCTURE); as a possible cause for the failure. The manufacturer was notified of the failure. The approximate failure mileage was 47,330.

This is a supplemental complaint to add more detail to a prior submission. I am the original owner of a 2021 Toyota Highlander with 10,000 miles at the time of the issue worsening to the point that I finally broke down and was forced to pay the Toyota dealership's hefty diagnostic fee. The air conditioning system has failed due to a refrigerant leak in the rear A/C lines, specifically near the exhaust area under the vehicle. The dealership diagnosed the issue and quoted me over $3,000 to replace “all necessary components in the rear.” They offered no coverage or goodwill repair despite the vehicle’s age and mileage. Upon researching the issue for longer than a year at this point, I discovered far too many similar complaints from other Highlander owners (years 2019–2021) describing identical failures — typically rear A/C lines corroding, cracking, or leaking prematurely. In some cases, customers were told Toyota is aware of the issue but not issuing a TSB or recall. In other cases, dealers said no permanent fix exists. These repairs are prohibitively expensive and, in some reports, recurring due to poor line placement or dissimilar metal corrosion near heat sources. This significantly impacts safety in several ways: Impaired Visibility: The AC system is integral to effective defogging and defrosting of the windshield, especially in humid or cold conditions. Without it, visibility is severely compromised, increasing the risk of an accident. Driver Impairment: In extreme temperatures, lack of climate control can lead to driver fatigue, distraction, and reduced concentration, posing an indirect safety risk. I am reporting it to request NHTSA monitor the trend. This seems to reflect a possible engineering or design flaw, and the number of similar owner reports suggests it may warrant further review by Toyota and NHTSA. Customers should not be facing multi-thousand-dollar repairs on near-new vehicles with basic systems failing. Thank you for tracking this issue.

Roof rails leak and allow water to enter the head liner and the air bags in the support arms of the cabin. Toyota has a Toyota Service Bulletin related to this but they and their dealers will not fix this. It would seem to be an issue if the air bags do not function as intended due to Toyota ignoring a manufacturing defect on their vehicles.

The contact owns a 2021 Toyota Highlander. The contact received notification of NHTSA Campaign Number: 23V720000 (Structure). The contact stated that while driving 30 MPH, an abnormal sound was coming from the front bumper. Upon inspection, the front bumper had partially detached from the vehicle. The vehicle was taken to the dealer; however, it was unknown if the vehicle was repaired. The contact also received notification of NHTSA Campaign Numbers: 23V865000 (Air Bags); however, the part to do the recall repair was not yet available. The vehicle was taken to the dealer. The vehicle was not repaired. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The manufacturer was made aware of the issue. The vehicle had been with the dealer for over one year. The failure mileage was approximately 15,000. Parts distribution disconnect.

The contact owns a 2021 Toyota Highlander. The contact stated that rainwater leaked into the roof panel into the front driver’s and passenger’s side door panels, causing a mildew odor inside the cabin of the vehicle. The vehicle was taken to the local dealer who discovered mold was present inside the panels of the vehicle. The contact was informed that the interior headliner and headliner clips needed to be replaced. The vehicle was not repaired. The manufacturer was notified of the failure, but no assistance was offered. The failure mileage was 5.

The contact owns a 2021 Toyota Highlander. The contact received notifications of NHTSA Campaign Numbers: 23V720000 (Structure) and 23V865000 (Air Bags); however, the part to do the recall repair was unavailable. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The manufacturer was made aware of the issue. The contact stated while driving 65 MPH, there was an abnormal sound coming from the front end of the vehicle and it felt like the front tires had struck an object on the highway. The contact stopped the vehicle and observed that the lower half of the front bumper had detached and was on the road surface. The contact called a local dealer and was informed that the parts were not yet available. The vehicle was not repaired. The failure mileage was approximately 31,000. VIN tool confirms parts not available.

Our Highlander has a recall for the clips on the front bumper. A few weeks ago, my wife was driving behind a truck pulling a trailer. My wife that it was a set of caster wheels that flew out from the trailer and made contact with her front bumper. Upon inspection the impact from that debris put a crack in the upper front bumper. No other visible damage was present. Later that day while my wife was driving 75 on the interstate, the defective clips from the recall gave way and the lower front bumper gave way and started to drag on the ground. Luckily it stayed in tack enough that the vehicle did not run it over causing my wife to wreck or even worse having other vehicles needing to avoid it on the interstate. We paid for a tow truck to safely take it off the interstate so we could tie wrap the lower bumper up and take it to the dealer. Toyota recall does warn that light impact to the bumper could result in the bumper falling. It also goes on to say that if the clips cannot be changed out, they will replace both the lower and upper bumpers. I took the car to the local dealer, and they confirmed that the clips could not be replaced due to the damage that had been done. I showed the dealer the recall notification on the internet, and they stated they could not do anything as they were not a body shop. So, I opened a complaint with Toyota Customer Care [XXX] ) and stated my case. They in turn notified a local dealer to address the issue. I have called customer care twice not without the dealer even trying to contact me. Due to there faulty part, my wife could have been in a much more serious accident. I would like your assistance in have Toyota make good on their commitment to replace both the lower and upper bumper as a result of the light contact that created this situation. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)