I own a 2024 Toyota Grand Highlander Hybrid MAX Platinum, purchased brand new in February 2024 and now with approximately 30,400 miles. Since the first few weeks, the vehicle has had an ongoing fuel tank/range issue. The fuel tank is rated at approximately 17 gallons, but the gas pump consistently shuts off after only 10–12 gallons, even when the vehicle indicates 0 miles to empty. It accepts approximately the same amount whether I refuel with 80, 20, or 0 miles remaining. After filling, the vehicle reports the tank as full and but generally shows only 270–290 miles of estimated range. The actual miles driven before requiring fill up is 230-250 miles. Toyota issued T-SB-0060-25 (Low Fuel Warning Light Logic Enhancement), which a Toyota dealer reluctantly performed on my vehicle. It initially improved the displayed range by only about 10 miles, but did not resolve the problem, and the condition is now worsening. The dealer solution was to tell me I can drive another 60-100 miles past empty but I do not believe that is a reasonable or safe workaround. This is because the driver cannot reliably determine the remaining usable fuel or how far the vehicle can safely travel. The condition remains unresolved and is a known issue with other Toyota Grand Highlander Hybrid Max owners.

Source: NHTSA complaint ODI #11763866 · view all complaints for this vehicle at nhtsa.gov

400lb animal strike, no warning lamps on, sensors was replaced from Toyota Ashland KY last year. My wife and 14 year old daughter was in the front seats. Traveling speeds was 55mph zone was traveling approx 45mph.

Source: NHTSA complaint ODI #11762670 · view all complaints for this vehicle at nhtsa.gov

The contact owns a 2024 Toyota Grand Highlander. The contact stated that the vehicle unexpectedly lurched forward while depressing the brake pedal. There was no warning light illuminated. The contact stated that excessive pressure was needed on the brake pedal to prevent the failure. The contact stated that a service appointment was scheduled with the dealer. While conducting independent research, the contact identified Technical Service Bulletin: T-SB-0028-25, which was associated with the vehicle shuddering while at a complete stop, and believed that the failure was associated with the technical service bulletin. The manufacturer was not notified of the failure. The vehicle was not repaired. The failure mileage was approximately 39,000.

Source: NHTSA complaint ODI #11754401 · view all complaints for this vehicle at nhtsa.gov

When making turns under acceleration at various speeds, there is a noticeable clunk noise from the front section of the vehicle. The sound can be described as a coil that is being compressed/decompressed and creates the noise. The noise is heard when loading and unloading the steering wheel during a turn.

Source: NHTSA complaint ODI #11733491 · view all complaints for this vehicle at nhtsa.gov

On February 25, 2025, I took my car into Freeman Toyota dealership in Santa Rosa for a recall on the airbags (24TA09 SAFETY (NONCOMPLIANCE) RECALL 24TA09(Remedy Notice) - Certain 2024 Model Year GrandHighlander and Grand Highlander HV - Curtain ShieldAirbags May Not Deploy As Intended). In the labor notes, they claimed to have performed the recall - 1. PERFORMED THE 24TA09 AND REPLACED BOTH LEFT AND RIGHT HAND CSA ASSEMBLIES. OP CODE: 24TA09R1.3.1 HRS. However, on June 24, 2025, the Toyota was involved in a collision with a deer. The autobody shop confirmed that the airbag sensors went off, but the airbags did not deploy. A claim was filed with my insurance company, and the airbags have been replaced by the autobody shop. The vehicle did not get back to the dealership.

Source: NHTSA complaint ODI #11723598 · view all complaints for this vehicle at nhtsa.gov

2024 Toyota Grand Highlander XLE FWD. At approximately 38,000 miles I began hearing a roaring/humming noise that varied with vehicle speed. The condition initially progressed slowly but then became much worse within several days. At 41,510 miles a Toyota dealer diagnosed and replaced the right rear hub/wheel bearing assembly. I was advised that the failed bearing was nearly seized when removed. After replacement the noise was reduced but remained present. The dealer was uncertain whether another bearing was failing and initially believed the remaining noise could be tire noise, advising me to monitor it. The noise again deteriorated rapidly and became severe enough that I considered the vehicle unsafe to drive. At 42,223 miles the same dealer diagnosed and replaced the left rear hub/wheel bearing assembly. The noise disappeared after replacement. Both rear wheel bearings therefore failed at approximately 40,000–42,000 miles within about 700 miles of each other. The vehicle has no known accident or suspension damage and the dealer identified no other condition causing the failures. I am concerned that rapid deterioration or seizure of a wheel bearing while driving could result in loss of vehicle control.

Source: NHTSA complaint ODI #11762946 · view all complaints for this vehicle at nhtsa.gov