2021 Toyota Highlander brake problems

SERVICE BRAKES

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.

NHTSA complaint #11755975 — an unverified report by a vehicle owner.

SERVICE BRAKES

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.

NHTSA complaint #11735875 — an unverified report by a vehicle owner.

SERVICE BRAKES

When slowing down to stop and the brake is depressed, multiple occasions where the brakes don’t catch. The car jerks forward and I am unable to engage the brakes. I have ended up in the middle of an intersection due to this. It happens frequently, and Toyota continues to brush me off.

NHTSA complaint #11724520 — an unverified report by a vehicle owner.

SERVICE BRAKES

•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.

NHTSA complaint #11717006 — an unverified report by a vehicle owner.

SERVICE BRAKES

Vehicle makes a loud noise when under 65mph. Car shakes when breaking. Transmission needs to be replaced.

NHTSA complaint #11716074 — an unverified report by a vehicle owner.

SERVICE BRAKES

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.

NHTSA complaint #11709958 — an unverified report by a vehicle owner.

SERVICE BRAKES

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.

NHTSA complaint #11706427 — an unverified report by a vehicle owner.

SERVICE BRAKES

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.

NHTSA complaint #11705290 — an unverified report by a vehicle owner.

SERVICE BRAKES

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.

NHTSA complaint #11700687 — an unverified report by a vehicle owner.

SERVICE BRAKES

When I apply my foot to the brake pedal the car slows, but just as I am about to reach the final part it feels like the brake is let go and the vehicle goes forward and I have to push harder on the brake to stop the vehicle. This issue can cause me to run into a vehicle that is stopped. I have not taken it to a dealer yet. No warning signs on the dash. This has been going on for about a year now.

NHTSA complaint #11699050 — an unverified report by a vehicle owner.

SERVICE BRAKES

My 2021 Toyota Highlander Hybrid has a braking issue identified in Toyota Service Bulletin T-SB-0059-23, Hybrid Regenerative Brake Transition Feeling Improvement. When going downhill and applying the brake, the vehicle lurches forward temporarily as the braking system transitions from regenerative to hydraulic braking. The first time my vehicle did this, it was very alarming and I had to take additional measures to slow my vehicle as I was driving downhill. My vehicle frequently demonstrates this problem, however, I did not report it to my local Toyota dealer because I read in an online chat group that it was a characteristic of this vehicle. Although the TSB recommends a Reprogram of the Brake Actuator Assembly Control Module, the repair is only covered under the Toyota Basic Warranty which is in effect for 36 months or 36k miles, whichever occurs first. My vehicle is past the warranty limit, and because I did not report it to my dealer previously, this repair is not covered under the TSB or the Toyota Basic Warranty. Toyota Highlander Hybrid model years 2020-2022 are affected. The Technical Service Bulletin was issued August 29, 2023, so if a 2020 model Highlander Hybrid has this problem, 2020 models would have already passed the warranty limit by the time the TSB was issued and thus would not be covered. This is a safety risk as drivers can lose control of the vehicle when braking, particularly when going downhill. The Warranty should be extended, or this problem should be elevated to a RECALL so that older affected vehicles, or those with higher mileage can be covered under warranty. Drivers should not have to pay for a recognized problem that affects the safety of this vehicle and has been identified in a Technical Service Bulletin. This problem puts drivers at risk of losing control of the vehicle and the problem can be mediated with a software reprogram. T-SB-0059.23 should be elevated to a RECALL, or extended regardless of age or mileage.

NHTSA complaint #11694237 — an unverified report by a vehicle owner.

SERVICE BRAKES

As your braking coming to a stop, the vehicle surges forward, feels like you lost your brakes and then it stops. If the car in front of you were to stop suddenly, you would hit them from behind. It had been going on for a while, but since it was my wife’s car she said she just stayed way back from the car ahead of her. I came within inches of hitting someone in early June 2025. I took the car to my Toyota dealer June 25, 2025 and they said there was a computer update for the braking system. It took away most of the problem, but it still surged.On August 19, 2025 I took the car back to the dealer where they had another computer update for the brakes. We will see if that works!! I feel it’s a safety issue, we should have been notified. Out of warranty cost me $348.01

NHTSA complaint #11681929 — an unverified report by a vehicle owner.

SERVICE BRAKES

Vehicle: 2021 Toyota Highlander XSE Approximate Mileage: 92,000 Location: Boerne, TX (Texas Hill Country) ⸻ 🔧 Summary of the Problem: My vehicle experienced serious electrical failure after heavy rainfall in the Texas Hill Country, where catastrophic flooding recently occurred. At a red light, the dashboard began flashing, power windows stopped working, and the electronic parking brake would not disengage. I was nearly rear-ended with my children in the car because the vehicle temporarily lost responsiveness. ⸻ 💧 Pattern of Issue: This problem only occurs after rain. Once the vehicle dries out, the systems return to normal. Toyota tested the battery and alternator and found no faults. The dealership and Toyota Corporate have been notified, but they have so far refused to approve a Goodwill Repair or perform deeper inspection for water intrusion into the fuse box, firewall harness, or Body Control Module (BCM). ⸻ 🧩 Suspected Cause: I believe there is water intrusion due to a design flaw, likely through the windshield cowl or firewall. Other Highlander XSE owners have reported nearly identical symptoms following rain exposure. Toyota has issued service bulletins in the past about water reaching electrical components in other models. ⸻ 📣 Safety Concern: This is a serious safety issue. A near-crash involving my children occurred. If Toyota does not resolve this issue and it leads to an accident, I will hold them fully accountable. I am reporting this so it can be formally investigated and linked with similar complaints.

NHTSA complaint #11671572 — an unverified report by a vehicle owner.

SERVICE BRAKES

My 2021 Toyota Highlander Hybrid has a braking issue identified in Toyota Service Bulletin T-SB-0059-23, Hybrid Regenerative Brake Transition Feeling Improvement. When going downhill and applying the brake, the vehicle lurches forward temporarily as the braking system transitions from regenerative to hydraulic braking. The first time my vehicle did this, it was very alarming and I had to take additional measures to slow my vehicle as I was driving downhill. My vehicle frequently demonstrates this problem, however, I did not report it to my local Toyota dealer because I read in an online chat group that it was a characteristic of this vehicle. Although the TSB recommends a Reprogram of the Brake Actuator Assembly Control Module, the repair is only covered under the Toyota Basic Warranty which is in effect for 36 months or 36k miles, whichever occurs first. My vehicle is past the warranty limit, and because I did not report it to my dealer previously, this repair is not covered under the TSB or the Toyota Basic Warranty. Toyota Highlander Hybrid model years 2020-2022 are affected. The Technical Service Bulletin was issued August 29, 2023, so if a 2020 model Highlander Hybrid has this problem, 2020 models would have already passed the warranty limit by the time the TSB was issued and thus would not be covered. This is a safety risk as drivers can lose control of the vehicle when braking, particularly when going downhill. The Warranty should be extended, or this problem should be elevated to a RECALL so that older affected vehicles, or those with higher mileage can be covered under warranty. Drivers should not have to pay for a recognized problem that affects the safety of this vehicle and has been identified in a Technical Service Bulletin. This problem puts drivers at risk of losing control of the vehicle and the problem can be mediated with a software reprogram. T-SB-0059.23 should be elevated to a RECALL, or extended regardless of age or mileage.

NHTSA complaint #11666516 — an unverified report by a vehicle owner.

SERVICE BRAKES

Since I got his vehicle i satated to the Toyota that having the breaks problem and dash is not working properly and blind spot is not working on time

NHTSA complaint #11645339 — an unverified report by a vehicle owner.

SERVICE BRAKES

While braking, the car often lurches forward (so much so that it will throw my head back against the headrest). It almost feels like the car accelerated even though I have my foot on the brake. It will "re-engage" but it is frightening and also unsafe if you are close behind another vehicle or object. I have also felt the car lurch forward while it was in park a few times. Again, completely scared me because I thought I was going to be pushed into my garage wall. These incidences do not happen every time but they shouldn't be happening at all. I understand the hybrid aspect of it with the brakes and expect a small sensation but to be lurched forward so much is completely unsafe. I initially told the dealership about the brake sensation shortly after punching the car in 2021 and was told there was nothing wrong. I now see hundreds of people posting on social media with the same problem. Toyota needs to do a recall and have this fixed. There are no warning lights or messages that appear when the problem takes place.

NHTSA complaint #11636049 — an unverified report by a vehicle owner.

SERVICE BRAKES

My brakes seem to have an issue at times and I am happy to provide it for inspection if needed. When traveling downhill with a slight curve to a stop at slower speeds, the car lunges forward for a second just after the brakes have been engaged. It does not happen all the time, but when it does happen it feels like you could crash into a car in front of you. This issue happens 2-4 times a month and has been happening since I purchased the vehicle. I recently found a Toyota forum with many people stating they have the same problem. Toyota does not seem to be aware of the issue when I have asked them. There have not been any warning lights etc. at any time during this issue nor any recalls with the issue. I am requesting it to be looked at by the manufacturer at the next scheduled service.

NHTSA complaint #11631677 — an unverified report by a vehicle owner.

SERVICE BRAKES

2021 Toyota Highlander Hybrid - experiences the sensation of brake loss during transitional period when car switches between regenerative brakes and mechanical brakes; most often occurs on a downgrade approaching a stop. During the transition, the car will surge ahead unexpectedly. I would consider this a significant safety issue; causes the driver to misjudge the required stopping distance and it is possible to hit something (or someone) in front of you. There is a TSB-0059-23 against this issue that requires a software update of the brake actuator. The issue is serious enough in my opinion that a recall of all Highlander hybrids is justified and Toyota should cover the cost of the update. The issue is intermittent and has occurred since new.

NHTSA complaint #11626133 — an unverified report by a vehicle owner.

SERVICE BRAKES

The vehicle is a hybrid. While traveling downhill at a speed around 35 mph with light brake pressure, the vehicle feels like it lurches forward a second or so before returning to braking. It has occurred since we purchased the vehicle new in 2021. It has happened multiple times in a variety of scenarios but it occurs most consistently in the downhill scenario described above.

NHTSA complaint #11611701 — an unverified report by a vehicle owner.

SERVICE BRAKES

The electric park brake makes a loud screaming sound during engaging cycle as I put the gear in park. The sound gets worse during warmer weather. I visited the dealer twice for the same problem and reported it to Toyota. During my visit another highlander came into dealership. It made the same sound when the driver placed it in Park. According to the dealer, this sound is normal. I say it’s not. I have way cheaper cars with Electric park and they don’t make this sound. If the park brake unit fails it’s going to be real costly to repair and may fail while driving and gets engaged.

NHTSA complaint #11604891 — an unverified report by a vehicle owner.

SERVICE BRAKES

When decelerating from a speed of approximately 25 mph on a downward slope of about 5 degrees, and applying the brakes, a number of things occur: 1) There is a 1-2 second delay in the braking action. 2) When applied the braking action is less than expected for certain brake pedal pressure, which causes the driver to increase the brake pedal pressure 3) When the brake pedal is initially depressed, the speed of the vehicle experiences a slight upward speed bump before the braking action is applied, which is 'light' as described in 2). This behavior is transient. Most of the time, it does not happen. It happens often enough to be of concern.

NHTSA complaint #11591720 — an unverified report by a vehicle owner.

SERVICE BRAKES

When braking, there is a momentary period where it feels like the brakes fail, then function again. When approaching stopped traffic, this could put those vehicle occupants, and our vehicle occupants at risk of an accident. Toyota maintains this is normal for a hybrid, however our 2013 Camry Hybrid has no such momentary brake failure. Our independent repair shop has been unable to replicate this condition , but they have found no obvious problems with the braking system - they believe it is something computer caused, likely when the hybrid generation brake switches to the hydraulic brake. There are no warning lights displayed. This has been a long standing issue.

NHTSA complaint #11591797 — an unverified report by a vehicle owner.

SERVICE BRAKES

The vehicle hesitates during right turns, creating a hazardous, potentially dangerous, situation. From research I understand this is a known issue when transitioning between battery and gasoline propulsion. Research indicates this is a known situation, Toyota T-SB-0059-23. However, the TSB expires at the termination of the vehicle 3 years/36 months warranty. As a safety issue, in my opinion this problem should be addressed, regardless of vehicle age or mileage.

NHTSA complaint #11591478 — an unverified report by a vehicle owner.

SERVICE BRAKES

While depressing the brake pedal the vehicle continues to accelerate before finally slowing to a stop. This happens on bumpy road surfaces as well as level road surfaces. There were no warning lights, alarms or messages prior to or during the failure. This issue started around 35,000 mileage and has progressively gotten worse to current day. (Current mileage as of 1/29/2024 is 54,346.) This issue would cause the vehicle to potentially rear end a vehicle you are following or propel the vehicle into an intersection typically controlled by a traffic signal or device. Local dealer has said there is nothing wrong as they could not replicate the issue.

NHTSA complaint #11568711 — an unverified report by a vehicle owner.

SERVICE BRAKES

I’ve had brakes inspected and was told my brakes look great. However there is major chattering coming off highway to slow on off ramp sometimes they don’t grab as they should and I have to be extra proactive. Sometimes steering back and forth quickly to slow vehicle until the brakes will work properly bringing vehicle to a stop or before a collision could occur

NHTSA complaint #11565819 — an unverified report by a vehicle owner.

SERVICE BRAKES

My 2021 Toyota Highlander Hybrid braking system has, since about 18 months ago, been intermittently failing. When coming to a stop, with my foot on the break, the break releases (or at least feels like it does) before coming to a full stop and then re-engages a moment later once I press harder. Such, gives one a start and is quit disconcerting. There have been times when I was sure the car was going to drift into an intersection. Also I am concerned that such breaking behavior may put pedestrians, cyclists, etc., at risk. I have on two occations reported this to the dealer. They have not been able to reproduce the problem, which is typical of intermittent problems. Tomorrow, December 11, 2023, they are looking at it again. No warning lights or messages have occured. Neither the manufacturer, insurance company, nor the police have inspected the vehicle.

NHTSA complaint #11559385 — an unverified report by a vehicle owner.

SERVICE BRAKES

Electronic parking brake not always disengaging and sending error.

NHTSA complaint #11553576 — an unverified report by a vehicle owner.