2008 Toyota Highlander Hybrid problems

Defect

Toyota Motor Company (Toyota) is recalling certain model year 2009-2011 Tundra, Sequoia, Corolla, Corolla Matrix and Scion xB, 2008-2011 Highlander and Highlander Hybrid, 2007 Camry and Camry Hybrid, 2009 Camry and Camry Hybrid, 2006-2011 RAV4, 2006-2010 Yaris, and 2009-2010 Scion xD and Pontiac Vibe vehicles. During the manufacturing of the Power Window Master Switch (PWMS), grease lubricant may have been inconsistently applied to the sliding electrical contacts.

Consequence

If the sliding electrical contacts are not protected by lubricant, debris and moisture that get into the switch may cause a short circuit and the switch assembly may overheat and melt, increasing the risk of a fire.

Remedy

Toyota will notify owners, and dealers will inspect the switch, applying a lubricant if no abnormality is found. If abnormality is found, the PWMS circuit board will be replaced, free of charge. The recall is expected to begin December 20, 2015. Owners may contact Toyota customer service at 1-800-331-4331. Toyota's number for this recall is C0M.

Defect

Toyota is recalling certain model year 2006-2010 Highlander hybrid vehicles manufactured February 16, 2005, through July 29, 2010; and model year 2006-2008 Lexus RX400h vehicles manufactured February 23, 2005, through December 2, 2008. The Intelligent Power Module (IPM) inside the inverter module may contain transistors that have higher operating temperatures than the solder can support and the transistors may be heat damaged by the solder. If this occurs, various warning lamps, including the malfunction indicator lamp, slip indicator light, brake system warning light, and master warning light, will be illuminated on the instrument panel.

Consequence

The vehicle may enter a fail-safe/limp-home mode that limits the drivability of the vehicle. It is possible that the hybrid system will shut down while the vehicle is being driven, causing the vehicle to stall unexpectedly, increasing the risk of a crash.

Remedy

Toyota will notify owners, and dealers will replace the IPM free of charge. Owners may contact Toyota at 1-800-331-4331. Vehicles that had their IPM replaced under recall 11V-342 are not affected by this campaign.

Defect

Toyota is recalling certain model year 2007-2009 Camry, Camry Hybrid, RAV4, Corolla, Corolla Matrix, Tundra, Sequoia, Highlander, Highlander Hybrid, Yaris, Scion xB, Scion xD and Pontiac Vibe vehicles. The power window master switch assemblies in some of these vehicles were built using a less precise process for lubricating the internal components of the switch assemblies. Irregularities in this lubrication process may cause the power window master switch assemblies to malfunction and overheat.

Consequence

If the switch overheats, it may melt, possibly resulting in a fire.

Remedy

Toyota will notify its owners, and dealers will inspect the switch and apply a special grease that inhibits heat build up or replace any switch damaged by the defect, free of charge. Toyota owners that experience a problem with a switch should not attempt to make repairs, but should contact their Toyota dealer or the Toyota Customer Experience Center at 1-800-331-4331. General Motors will contact the Pontiac Vibe owners affected by this recall and GM dealers will inspect and repair switches as necessary. Those owners may contact Pontiac Customer Care at 1-800-762-2737.

Defect

TOYOTA IS RECALLING CERTAIN MODEL YEAR 2008 HIGHLANDER, HIGHLANDER HYBRID, AND MODEL YEAR 2007-2008 RAV4 VEHICLES. IN THE CURTAIN SHIELD AIRBAG (CSA) SYSTEM, THERE ARE TWO SENSORS IN THE AIRBAG SENSOR ASSEMBLY WHICH ARE DESIGNED TO DETECT VEHICLE ROLL ANGLE. IF ONE OF THESE SENSORS MALFUNCTIONS, THE AIRBAG WARNING LIGHT (MALFUNCTION INDICATOR LIGHT: MIL) WILL ILLUMINATE AND THE ROLL DETECTION SYSTEM WILL BE SUSPENDED; HOWEVER, THE AIRBAG CSA REMAINS AVAILABLE IN THE EVENT OF A SIDE CRASH. IF BOTH SENSORS FAIL NEARLY SIMULTANEOUSLY AFTER INITIAL AIRBAG SYSTEM CHECK, THE CSA AND THE SEAT BELT PRETENSIONER COULD BE INADVERTENTLY ACTIVATED.

Consequence

INADVERTENT ACTIVATION OF THE CSA AND/OR THE SEAT BELT PRETENSIONER CAN CAUSE INJURY TO A VEHICLE OCCUPANT.

Remedy

TOYOTA WILL REPLACE THE AIRBAG SENSOR ASSEMBLY WITH A NEW ONE CONTAINING IMPROVED ROLL RATE SENSORS, FREE OF CHARGE. TOYOTA INTENDS TO SEND AN INTERIM OWNER NOTIFICATION TO OWNERS EARLY TO MID-MAY, 2011 WHEN SUFFICIENT PARTS AND REMEDY BECOMES AVAILABLE. OWNERS MAY CONTACT TOYOTA AT 1-800-331-4331.

Defect

TOYOTA IS RECALLING 27,080 MODEL YEAR 2005 THROUGH 2010 PASSENGER CARS BUILT FROM SEPTEMBER 1, 2005 TO MAY 4, 2009. THESE VEHICLES WERE NOT EQUIPPED WITH LOAD CARRYING CAPACITY MODIFICATION LABELS WHICH FAILS TO CONFORM WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 110, "TIRE SELECTION AND RIMS."

Consequence

INCORRECT LOAD CARRYING CAPACITY MODIFICATION LABELS COULD RESULT IN THE VEHICLE BEING OVERLOADED, INCREASING THE RISK OF A CRASH.

Remedy

TOYOTA WILL NOTIFY OWNERS AND PROVIDE THEM WITH A NEW, ACCURATE LABEL TO BE INSTALLED OVER THE INACCURATE LABEL FREE OF CHARGE. THE SAFETY RECALL BEGAN ON AUGUST 18, 2009. OWNERS MAY CONTACT TOYOTA AT 1-888-270-9371.

Defect

SOUTHEAST TOYOTA IS RECALLING 3,499 STAINLESS STEEL EXHAUST TIPS SOLD BY SOUTHEAST TOYOTA AS AN OPTIONAL ACCESSORY FOR USE ON MY 2008 HIGHLANDER AND HIGHLANDER HYBIRD VEHICLES. DUE TO IMPROPER HEAT TREATMENT DURING THE MANUFACTURING PROCESS, THE ORIGINAL CLAMP USED TO SECURE THE STAINLESS STEEL EXHAUST TIP TO THE EXHAUST PIPE MAY DEVELOP MICROSCOPIC CRACKS. EVENTUALLY THE CRACK MAY EXPAND CAUSING THE CLAMP TO BREAK.

Consequence

THE ORIGINAL CLAMP AND THE TOYOTA STAINLESS STEEL EXHAUST TIP MAY FALL OFF THE VEHICLE'S EXHAUST PIPE AND BECOME A ROAD HAZARD WHICH WOULD INCREASE THE RISK OF A VEHICLE CRASH.

Remedy

SOUTHEAST TOYOTA WILL NOTIFY OWNERS AND REPLACE THE CLAMP FREE OF CHARGE. THE SAFETY RECALL IS EXPECTED TO BEGIN DURING MAY/JUNE 2009. OWNERS MAY CONTACT SOUTHEAST TOYOTA CUSTOMER LOYALTY DEPARTMENT AT 1-800-301-6859.

Defect

TOYOTA IS RECALLING 39,100 STAINLESS STEEL EXHAUST TIPS SOLD BY TOYOTA AS AN OPTIONAL ACCESSORY FOR USE ON MY 2008 HIGHLANDER AND HIGHLANDER HYBRID VEHICLES. DUE TO IMPROPER HEAT TREATMENT DURING THE MANUFACTURING PROCESS, THE ORIGINAL CLAMP USED TO SECURE THE TOYOTA STAINLESS STEEL EXHAUST TIP TO THE EXHAUST PIPE MAY DEVELOP MICROSCOPIC CRACKS. EVENTUALLY THE CRACK MAY EXPAND CAUSING THE CLAMP TO BREAK.

Consequence

THE ORIGINAL CLAMP AND THE TOYOTA STAINLESS STEEL EXHAUST TIP MAY FALL OFF THE VEHICLE'S EXHAUST PIPE AND BECOME A ROAD HAZARD WHICH WOULD INCREASE THE RISK OF A VEHICLE CRASH.

Remedy

TOYOTA WILL NOTIFY OWNERS AND REPLACE THE CLAMP FREE OF CHARGE. THE SAFETY RECALL BEGAN ON MAY 4, 2009. OWNERS MAY CONTACT TOYOTA CUSTOMER EXPERIENCE CENTER AT 1 888-270-9371 MONDAY THROUGH FRIDAY, 5:00 AM TO 6:00 PM, SATURDAY 7:00 AM THROUGH 4:00 PM PACIFIC TIME.

Defect

TOYOTA IS RECALLING 90,189 MY 2008 HIGHLANDER AND HIGHLANDER HYBRID PASSENGER VEHICLES EQUIPPED WITH A THIRD ROW SEAT. THESE VEHICLES FAIL TO CONFORM TO THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 208, "OCCUPANT CRASH PROTECTION." THE NON-DRIVER DESIGNATED SEATING POSITIONS (DSP) ON THESE VEHICLES IS EQUIPPED WITH SEAT BELT ASSEMBLIES THAT HAVE A FEATURE THAT CONVERTS THE RETRACTOR FROM AN EMERGENCY LOCKING RETRACTOR (ELR) TO AN AUTOMATIC LOCKING RETRACTOR (ALR). THE BELTS CONVERT TO THE ALR MODE AFTER THE WEBBING HAS BEEN FULLY WITHDRAWN FROM THE RETRACTOR. THE SYSTEM IS DESIGNED SO THAT AS THE BELT IS RELEASED INTO THE RETRACTOR, THE SYSTEM REMAINS IN THE ALR MODE SO THAT A CHILD RESTRAINT SYSTEM (CRS) CAN BE TIGHTLY SECURED.

Consequence

HOWEVER, FOR THE TWO THIRD ROW DSP'S ON THESE VEHICLES, THE ALR MODE DEACTIVATES BEFORE THE WEBBING IS FULLY RETRACTED, SO THAT IT WILL NOT LOCK WHEN CERTAIN REAR-FACING CRS'S THAT HAVE A SHORT SEAT BELT ROUTING PATH ARE INSTALLED IN THE VEHICLE. THIS CAN ALLOW THE SEAT BELT WEBBING TO SPOOL OUT DURING NORMAL DRIVING MANEUVERS, WHICH COULD AFFECT THE STABILITY OF A CHILD RESTRAINT INSTALLED AT THOSE SEATING POSITIONS. AS SUCH, THIS COULD DISCOURAGE THE USE OF A CHILD RESTRAINT AND IN THE EVENT OF A CRASH, THE CHILD MAY NOT BE ADEQUATELY PROTECTED POSSIBLY RESULTING IN INJURY.

Remedy

DEALERS WILL INSTALL A NEWLY DESIGNED SEAT BELT COMPONENT FREE OF CHARGE. THE RECALL IS EXPECTED TO BEGIN ON OR ABOUT DECEMBER 18, 2008. OWNERS MAY CONTACT TOYOTA AT 1-800-331-4331.