Toyota Grand Highlander body problems

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A rock went through the grill and pierced the AC condenser. The result left us with no AC. Toyota of Grand Rapids charged us $2300 to replace it. The holes in the grill are massive. Toyota of Grand Rapids has a video on file documenting the issue.

NHTSA complaint #11758738 — an unverified report by a vehicle owner.

STRUCTURE:BODY

Front bumper grille too large. I see lots of bugs stuck on top of radiator. Very exposed for rocks to enter and damage cooling systems.

NHTSA complaint #11758691 — an unverified report by a vehicle owner.

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My 2026 Toyota Grand Highlander Platinum has an issue that is commonly referred to as "cabin boom". It occurs at approximately 30mph going over bumps or rough patches in the road. When it occurs it creates a droning noise that amplifies the bump or rough surface you drove over and also creates a cabin pressure similar to flying on an airplane. This issue has caused significant ear pressure and headaches from driving my brand new vehicle. As a chronic migraine sufferer, this is unacceptable when you commute 25 miles to and from work. The issue has been reproduced by the Toyota dealership and they are currently in a waiting phase of next steps from Toyota corporate engineers on how to fix the issue, however there is no timeline on a resolution. Considering this has been an issue for over two years I find it unacceptable. They have added sound proofing materials around the spare tire and that didn't help the issue at all. This has apparently been an issue since the first Grand Highlander model was released, however it seems to not affect all of them but does affect across all trim levels.My dealership just got two brand new Grand Highlanders in this past week, and they make the same exact sound. I'm hoping with more reports of the issue Toyota will actually address it because I know of many other owners who have this problem. Other owners have taken these same steps over the past two years with no results. Please help make Toyota recognize and figure this out.

NHTSA complaint #11758692 — an unverified report by a vehicle owner.

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Driving on highway and suddenly panoramic sunroof glass shattered spontaneously. It nearly caused us to crash into median due to the sudden extremely loud noise that sounded like a gunshot at close range and then the sound of glass shattering and hitting into sunroof shade and top of car. My 18 year old daughter was driving and it was extremely scary for her and myself. No nearby vehicles on either side of the road or near an overpass. We were fortunately near an exit and able to safely remove vehicle from road. I feel extremely lucky that no accident or injury occurred and credit my daughter's ability to stay calm and not panic at highway speed. To date, the car insurance company Travelers states it is not covered as there was no accident and dealership states it is not a warranty item (but they have escalated it to Toyota corporate for further review) and no one is willing to repair it so far (including stand alone glass companies!). But it will certainly be several thousand dollars in repairs. In the meantime I cannot drive my car when there is any chance of rain or really at highway speed. No warning prior, no history of any cracks or damage to sunroof prior. The car is just barely 1 year old.

NHTSA complaint #11753991 — an unverified report by a vehicle owner.

STRUCTURE:BODY:HOOD

My 2026 Toyota Grand Highlander exhibits abnormal fluttering/vibration of the hood at speeds above approximately 25 mph. I have identified that this is the same defect documented in Toyota's own Technical Service Bulletin T-SB-0111-24 (issued December 4, 2024), which addresses this condition on 2024 model year Grand Highlander and Grand Highlander Hybrid vehicles, with the same complaint widely reported by 2025 model year owners as well. Despite this being a known, documented Toyota defect for three consecutive model years, I have been unable to get it resolved through Toyota's official channels: I contacted Toyota's PATT Lab (Parts and Technical Assistance) regarding the vibration under Dealership Task Number DC261970283. PATT Lab informed me that other 2026 model year vehicles exhibit the same condition, characterized it as "intended behavior," and closed the task without applying the known TSB remedy. I was directed to Toyota Brand Engagement for further assistance. This was opened as Case Number 260722000822. Toyota Brand Engagement stated they are not mechanics and that the issue must be resolved at the dealership level, but has provided no directive or authorization to the dealership to perform the known TSB repair. As a result, I am caught in a loop between Toyota corporate departments, none of which will authorize or perform the fix that Toyota's own engineering team has already documented and issued a bulletin for. My vehicle has a known manufacturing/design defect that Toyota has acknowledged in writing for prior model years, yet I am being told simultaneously that it is "normal" and that it's a dealership matter — while no dealership has been given authorization to apply the remedy. Requested Action: I am requesting that Toyota Motor Sales, USA be required to apply the existing Technical Service Bulletin remedy (or its 2026 model year equivalent) to my vehicle at no cost, consistent with how this defect has already been addressed for 2024 and 2025 mod

NHTSA complaint #11752112 — an unverified report by a vehicle owner.

STRUCTURE:BODY:HOOD

“The aluminum vehicle hood exhibits severe, abnormal fluttering and vibration across the rear-center section when driving at highway speeds (approx. 55-70+ mph). This movement is constant and highly distracting, creating a safety hazard by drawing the driver's attention away from the road and causing concern about the structural integrity of the hood latch system. Despite having the manufacturer's recommended repair (T-SB-0111-24) performed by an authorized dealership, the condition persists without improvement. I am concerned the hood could eventually unlatch or detach completely at high speeds, posing a danger to myself and other motorists.”

NHTSA complaint #11737282 — an unverified report by a vehicle owner.

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While i was closing the trunk Did press area below my license plate to close the trunk, and got a dent below the license playe. Looks like very poor quality of steel being used

NHTSA complaint #11736903 — an unverified report by a vehicle owner.

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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 .

NHTSA complaint #11736129 — an unverified report by a vehicle owner.

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I was driving on in the left most lane on a highway at 70 miles speed with multiple trucks speeding from behind. My car suddenly lost acceleration and saw multiple warning messages on my car display. I barely managed to save my car from being hit by the trucks speeding from behind, applying emergency lights and steering my vehicle from the left lane to the right side of the highway. After towing the car to nearest dealer I understood that a stone went through the front grill of the car and it got the radiator converter leaking all the coolant and that created the loss of acceleration. This is a safety issue in the design of the car grill as it has unusually large holes leaving a critical part vulnerable and failure leads to loss of acceleration and a safety hazard. For similar other hybrid models in Lexus or Toyota Sienna the same grill is protected with smaller vents in the grill.

NHTSA complaint #11735710 — an unverified report by a vehicle owner.

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While driving at approximately 20-25 mph, the panoramic sunroof glass of my vehicle suddenly shattered without any warning. There was no impact from road debris, no visible chip, and no prior damage to the glass. The glass appeared to explode outward, creating a loud noise and causing shattered glass to fall inside the vehicle. This created a dangerous situation that could have led to driver distraction or injury. Safety Concern: This incident poses a serious safety risk. Sudden shattering of the sunroof while driving can: Distract the driver and lead to loss of control Cause injury from falling or flying glass Create hazardous driving conditions, especially at highway speeds Dealer Response: I reported the issue to a Toyota dealership, but they denied warranty coverage, stating it was not covered without providing evidence of impact damage. Additional Notes: There was no visible point of impact, which suggests a possible stress fracture or manufacturing defect rather than external damage. Request: I request that NHTSA investigate this issue as a potential defect, as spontaneous sunroof glass failure while driving presents a significant safety hazard.

NHTSA complaint #11732822 — an unverified report by a vehicle owner.

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We were going down the highway in our brand new Grand Highlander yesterday (3500 miles, 3 months old) and it was like a bomb had gone off. The panoramic sunroof exploded up and out. Glass started falling on my daughter whom was in the middle seat. My husband had to quickly pull off the highway to safety. I have never experienced anything like this and it was extremely scary. Obviously there is a defect that needs to be addressed.

NHTSA complaint #11718364 — an unverified report by a vehicle owner.

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On 11/02/2025 with the cruise at 55mph all glass closed. Heater on with no vehicles around, the sunroof exploded. It pushed up from the inside. With less than 9k miles on the vehicle. It took my dealer 8 days to look at it then Toyota denied the warranty. Then Quoted me over $2,100 to replace. This vehicle isn't safe to drive as told to me from the dealer.

NHTSA complaint #11698699 — an unverified report by a vehicle owner.

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I am writing to report a serious issue with my 2025 Toyota Grand Highlander Hybrid (VIN: [XXX] ), purchased on [XXX] from Hillside Toyota . I have noticed water leaking from the top of the windshield, dripping onto the steering wheel and dashboard, particularly during rain or after a car wash. This issue began on [XXX] and I saw couple of times under these conditions, posing a potential safety hazard due to driver distraction and possible damage to electrical components. I have taken the vehicle to Hillside Toyota on 05/05/25 and 07/21/25 where they inspected the vehicle but could not identify the source of the leak” or “attempted a repair, but the issue persists. This issue is concerning, as it affects the safety and functionality of my vehicle, which has only 1184 miles INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA complaint #11677229 — an unverified report by a vehicle owner.

STRUCTURE:BODY:HOOD

Hood on 2025 Toyota Grand Highlander vibrates/flutters due to poorly designed aluminum construction. Very distracting and causes drivers to take eyes off the road. Toyota has issued T-SB-0111-24 for the 2024 Grand Highlander for this specific issue but my dealership told me that it doesn't apply to the 2025 but the hood part number is the same for both years. The constant vibration could eventually "work harden" the thin metal and ultimatlly allow the hood to break off the vehicle. Check out the old Jimmy Stewart movie when the constant vibration made the tail break off the airplane.

NHTSA complaint #11668805 — an unverified report by a vehicle owner.

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When going over rough or uneven roads, the car produces a strong low-frequency resonance, like a bass-heavy "boom". This causes a very uncomfortable feeling of pressure changing in my ears, gives me a headache and ear pain whenever I drive in local roads, which is the majority of driving in my area. This causes me to need to pull over and stop the car frequently to readjust my hearing. I've found many reports from others of the same issue but Toyota have not acknowledged it or found a solution.

NHTSA complaint #11667916 — an unverified report by a vehicle owner.

STRUCTURE:BODY:HOOD

The 2024 and 2025 Toyota Grand Highlander has excessive hood shaking and vibration at the rear of the vehicle. It is directly under the projection area of the windshield and directs your attention to the movement. At highway speeds the shaking is excessive. Toyota has not been able to find a repair for this issue.

NHTSA complaint #11651922 — an unverified report by a vehicle owner.

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Driving at low speeds through my neighborhood, when going on any bumpy road there is a terrible low bass noise. similar to a sub woofer very low bass. it is very annoying and distracting.

NHTSA complaint #11627132 — an unverified report by a vehicle owner.

STRUCTURE:BODY:HOOD

The hood of the vehicle flexes a lot at highway speeds, and it causes a lot of distraction if the sun is reflected on it. My concern is how much distraction it causes

NHTSA complaint #11622092 — an unverified report by a vehicle owner.

STRUCTURE:BODY:HOOD:HINGE AND ATTACHMENTS

The hood of the vehicle flexes a lot at highway speeds, and it causes a lot of distraction if the sun is reflected on it. My concern is how much distraction it causes

NHTSA complaint #11622092 — an unverified report by a vehicle owner.

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Air bags recall with no resolution. Recall announcement was release in June 19 big safety concern for our family, especially with the cost of the vehicle. We dont trust and won’t feel safe with a airbag replacement

NHTSA complaint #11610619 — an unverified report by a vehicle owner.