2024 Toyota Grand Highlander

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.

The hybrid inverter cooler failed due to an impact with what was described as a rock or road debris shooting through the front grill and striking the inverter cooler so that it leaked coolant and failed. There was no notice of impact, while driving on the highway the hybrid system rapidly went into shut down/safety mode and acceleration and power to the drivetrain of vehicle dramatically reduced. This took a matter of seconds while on the highway without any warning. The problem, cause, effect, and repair was all diagnosed by a Toyota service personnel at a Toyota dealer. It was reported that this is a common issue with the grill design.

It was noted that the drivers door weather strip deteriorated even though the car is less than 3 years old/ 47,000 miles. The dealer and the Toyota customer care said it is likely related to external factors and not covered under warranty. I keep the car in a garage. We have had other cars that are well over 10 years old but do/did not have this problem. This can potentially lead to damage of other components. I see on the internet that other owners of this car have encountered this same issue . There have been 3 safety recalls on this model, related to air bag, instrument panel and rear view camera. These have been fixed. There have been at least 5 Toyota technical service bulletins ( TSBs) published on this model. These were fixed after I brought it up with the dealer/ manufacturer. I was not contacted by the manufacturer proactively. TSB 0017-24 : hesitation felt while accelerating from stop. A software update was performed. TSB 0060-25 : Fuel level logic enhancement. A software update was made. TSB 0028-25 : Shudder sensation at stop. A software update was performed. ​T-SB-0082-24: CV axle issue: it was fixed T-SB-0111-24: vibrating hood.I notice the issue but did not fix it since the fix involves placing a foam under the hood, which may not fix the underlying issue and might cause other issues. I believe these issues are related to the manufacturing oversight and especially more frequent because it is a first year model .

Subject: NHTSA Complaint - 2024 Grand Highlander Hybrid XLE Rear Windshield Shattering To Whom It May Concern, I am writing to formally file a complaint regarding a concerning incident with my recently purchased 2024 Grand Highlander Hybrid XLE. On [XXX], 2024, the rear windshield/liftgate glass spontaneously shattered without any apparent cause. The vehicle was merely six months old at the time of the incident. This unexpected and potentially hazardous occurrence has prompted me to investigate further, and I have come across multiple reports online from other customers who have experienced similar issues with the same rear windshield/liftgate glass on this specific vehicle model. This pattern of incidents raises significant concerns about a potential manufacturer's defect that may compromise the safety and reliability of these vehicles. Given the frequency of such occurrences and the potential safety implications involved, I am urging the National Highway Traffic Safety Administration (NHTSA) to investigate this matter thoroughly. It is imperative to identify any underlying issues or defects that may be contributing to these incidents to ensure the safety of consumers and prevent any potential accidents or injuries in the future. Please consider this complaint as an urgent matter, and I implore the NHTSA to take appropriate action to address this issue promptly. Your attention to this matter is greatly appreciated, and I look forward to a swift and comprehensive investigation into this concerning issue. Sincerely, [XXX] [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)