2021 Toyota Highlander

My 2021 Toyota Highlander, purchased with 16k miles, has a leak in the AC system in the rear of the vehicle (as of May 2025, at 3 years 10 months into the vehicle's service, with 28k miles). This pipe runs the length of the car and costs $2000-$3000 to repair. This was confirmed at an independent service center that used leak detection dye to identify the problem. I am finding multiple reports of people having this problem in young Toyota vehicles (<4 years old) and with low miles. I believe this is a design flaw and not indicative of normal corrosion, as the vehicle does not exhibit corrosion elsewhere in the under carriage.

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.

Toyota continues to knowingly not remedy an airbag sensor issue. My vehicle has the light on indicating it is suffering from the same recall. I bought this car from them in 2024 and they sold it to me with the knowledge that there was a safety issue. I’ve tried to find a solution as this is a major safety issue. Toyota took my money in full for the car, yet can only offer me a loaner for 25 days. They said in CA, it most likely won’t get fixed until the end of 2026. I don’t have money. I have one car and I need a vehicle to transport to work and kids to school. This is not right and this is not safe. A remedy for people in CA that won’t be fixed for two more years that is an ACTUAL SAFETY issue , is not right. This is to document the safety complaint as the dealership continues to ignore the issue, and the 1-800 Toyota line continues to ignore it. All BBB complaints shows I’m not the only one. I can’t take a rental because they won’t pay me back, it’s not guaranteed, and I’m out another $40,000. They put people in impossible situations. The manager at the service center it’s your fault if you walk out of here without taking a loaner. You’re choosing to put your family at risk. And I said no, you’re offering me a loaner and you can’t guarantee a vehicle that will fit my family. I don’t know what to do.

The rear hatch has been causing me issues for quite a while. Last year, I would have to hit the close button once or twice for it to close. It would close a few inches, beep, and then stop. It has become much worse the last six months. I have to manually close the hatch myself because it won't go down all the way using the button. We took it to Cedar Rapids Toyota and they said this is a very common issue in this vehicle. They adjusted the hatch and lubricated it. Once they were done, they said it doesn't work any better. It costs over $1,000 to replace the parts and they can't get the parts until June because so many people are having the same issue. This vehicle needs to be recalled. Thanks,

Subject: Transmission Issue – 2021 Toyota Highlander Dear NHTSA, I am reporting a serious transmission issue with my 2021 Toyota Highlander (82,000 miles). I recently took it to the dealership for an unusual noise, and they diagnosed a transmission failure, quoting over $9,000 for replacement and service. After researching, I discovered Toyota has known about transmission issues in the 2021 Highlander since at least 2021. I have always serviced my vehicle at the same dealership, yet they never informed me of this known defect. Instead, they waited until my warranty expired to disclose the issue, despite my repeated maintenance visits where I reported the noise. I also found a 2021 Toyota document acknowledging transmission problems in this model, and many other owners have reported the same issue. It seems dealerships avoided addressing this until warranties expired, leaving owners with massive repair costs. This raises serious concerns about Toyota’s handling of known defects. I urge the NHTSA to investigate and take action to protect consumers from unfair repair costs and potential safety risks.