2004 Toyota Highlander SERVICE BRAKES, HYDRAULIC

BROUGHT THE VEHICLE IN FOR A ROUTINE OIL AND FILTER REPLACEMENT. AS DEALERS NORMALLY DO, THEY ALSO DID SPOT CHECKS ON BRAKES, HOSES, ETC. THE TWO FRONT WHEELS HAD BEEN REMOVED SUPPOSEDLY TO CHECK THE WEAR ON THE BRAKE PADS. AS THE MECHANIC WAS REINSTALLING THE WHEELS, TWO OF THE LUGS BROKE OFF. THE SERVICE REP SHOWED ME ONE AS HE EXPLAINED WHY THE OIL AND FILTER JOB WAS TAKING MUCH LONGER THAN EXPECTED. I STUDIED THE FRACTURE FACE AND SAW TYPICAL FATIGUE FAILURE WITH ORIGIN AND PROGRESSION FEATURES. IT WAS QUITE EVIDENT THE PROBLEM STARTED MUCH EARLIER THAN TODAY. I ONLY SAW ONE BROKEN LUG, BUT THE SERVICE REP SAID THAT THERE WERE TWO LUGS THAT BROKE PREMATURELY WHEN THEY WERE REINSTALLING ONE WHEEL. THIS CONCERNS ME SO I AM GIVING THIS INFORMATION TO NHTSA. I HAVE TAKEN CLOSE-UP PICTURES OF THE FRACTURE FACE IF YOU WOULD LIKE THEM SUBMITTED. TO BE SAFE, I AM HAVING ALL THE FRONT WHEEL LUGS REPLACED ON THIS VEHICLE. AGREED, THIS ISN'T NECESSARILY A TOYOTA PROBLEM. IT COULD HAVE BEEN CAUSED BY OVERTORQUE WHEN I HAD THE TIRES REPLACED. IF IT IS A TOYOTA PROBLEM, YOU'LL HAVE OTHER REPORTS SIMILAR TO MINE. (I AM A RETIRED SR. QUALITY ENGINEER FAMILIAR WITH ACCIDENT INVESTIGATION, FAILURE MODES, METALLURGY, METALLOGRAPHY, MACHINING PRACTICES, THREADS, ETC.) *TR

CABIN BRAKE ASSEMBLY BRACKET BENDS WHEN APPLYING THE BRAKES DURING (BUT NOT LIMITED TO) EMERGENCY STOPPING. THIS MOVEMENT CAUSES THE EDGE OF THE BRAKE PIVOT BOLT TO HANG ON THE UPPER BRAKE ASSEMBLY, LOCKING THE BRAKE PEDAL TO THE FLOOR AND PREVENTING THE BRAKE FROM DISENGAGING. ADDITIONALLY, WHEN THIS DOES OCCUR, LOSS OF ADEQUATE BRAKE LEVERAGE AND/OR SUDDEN CHANGE IN PROXIMITY OF THE BRAKE PEDAL TO THE FLOOR MAY PREVENT THE DRIVER FROM APPLYING THE BRAKES TO THEIR INTENDED CAPACITY. THIS IS OF PARTICULAR CONCERN DURING AN ACCIDENT AVOIDANCE SITUATION WHEN ADEQUATE FOOT PRESSURE FAILS TO ENGAGE THE VEHICLE'S ABS. THIS DIRECTLY LEADS TO INCREASED DANGER OF INJURY/FATALITY TO DRIVERS, PASSENGERS, OCCUPANTS OF OTHER VEHICLES, AND PEDESTRIANS. TOOK VEHICLE TO DEALER TO ADDRESS THIS DEFECT. DEALER REFUSED TO REMEDY THIS SAFETY DEFECT AT NO COST TO CUSTOMER. *TR

TL* THE CONTACT OWNS A 2004 TOYOTA HIGHLANDER LIMITED. THE CONTACT WAS DRIVING 45 MPH WHEN THE VEHICLE ABNORMALLY BEGAN TO VEER OFF THE ROAD. THE CONTACT APPLIED THE BRAKES AND THE VEHICLE THEN SUDDENLY SPUN AROUND AND CRASHED INTO A RAVINE. THE VEHICLE ROLLED OVER TWICE. THE CONTACT SUSTAINED INJURIES TO THE NECK AND BACK AND WAS ADMITTED TO THE HOSPITAL FOR TWO DAYS. A POLICE REPORT WAS AVAILABLE. THE VEHICLE WAS DESTROYED. THE VEHICLE WAS TOWED BY THE CONTACTS INSURANCE COMPANY. THE CONTACT STATED THAT PRIOR TO THE CRASH, AN UNKNOWN WARNING LIGHT WAS ILLUMINATED AND THE VEHICLE WAS TAKEN TO THE DEALER. THE DEALER MADE REPAIRS TO THE VEHICLE AND THE LIGHT WAS NO LONGER ILLUMINATED. NEITHER THE DEALER NOR THE MANUFACTURER WAS NOTIFIED OF THE FAILURE AND CRASH. THE FAILURE MILEAGE WAS 73,000. UPDATED 01/14/11*LJ

ONE WEEK AGO, WHEN I STEPPED ON THE BRAKE, A LOUD GRINDING NOISE WOULD HAPPEN. I SCHEDULED A APPOINTMENT WITH GOODYEAR TO HAVE MY BRAKES CHECKED. 2 DAYS BEFORE MY APPOINTMENT DATE, I ALSO HAD TO PRESS THE BRAKE PEDAL ALL THE WAY DOWN TO THE FLOOR TO GET THE CAR TO STOP. I FREAKED OUT AND WENT STRAIGHT TO GOODYEAR FOR THE REPAIR. THEY TOLD ME THAT THE RUBBER ON THE MASTER CYLINDER HAD BEEN EATEN AWAY BY THE BRAKE FLUID AND HAD TO BE REPLACED. THE WAS A RECALL IN 2001 FOR THE TOYOTA HIGHLANDER FOR THE SAME PROBLEM. I HAVE A 2004 HIGHLANDER. *TR

I PURCHASED A TOYOTA HIGHLANDER 4DR 4WD 4ECT AS A PREVIOUSLY OWNED VEHICLE WITH A PREVIOUSLY OWNED VEHICLE WARRANTY. AFTER OWNING AND USING THE VEHICLE FOR A FEW MONTHS WHILE DRIVING IN A TRAFFIC SITUATION, THE RIGHT SIDE REAR BRAKE SUDDENLY LOCKED UP INTERMITTENTLY ACCOMPANIED BY SWERVING, BY PANEL VSC LIGHT FLASHES AND AN AUDIBLE WARNING. THIS SITUATION FORTUNATELY OCCURRED NEAR OUR RESIDENCE ON DRY PAVEMENT. BY DRIVING VERY SLOWLY WE MANAGED TO GET THE VEHICLE TO A SAFE LOCATION. IT WAS THEN TOWED TO A LOCAL TOYOTA DEALER WHERE IT WAS INSPECTED AND THE FOLLOWING DIAGNOSIS OR SIMILAR WAS PROVIDED: CUSTOMER STATES THAT THE VSC LIGHTS ARE COMING ON AND THE BRAKES ARE LOCKING UP, YAW RATE SENSOR IS OUT OF CALIBRATION. RECALIBRATED YAW RATE SENSOR. THE VEHICLE WAS RELEASED TO US AS REPAIRED. THE PRECISE SAME VSC FAILURE SITUATION OCCURRED ON OCTOBER 11TH OF THIS YEAR AND AGAIN WE WERE LUCKY TO HAVE BEEN IN A REASONABLY SAFE LOCATION AND DRIVING UNDER GOOD ROAD CONDITION WHEN IT HAPPENED. THE VEHICLE WAS PICKED UP AND TOWED AGAIN TO THE DEALER FACILITY FOR ANALYSIS AND REPAIR. WE RECEIVED THE DIAGNOSIS: ?ELECTRICAL REPAIR, CUSTOMER STATES THAT THE VSC LIGHTS ARE COMING ON, AND THE BRAKES ARE LOCKING UP, YAW RATE SENSOR IS OUT OF CALIBRATION. RECALIBRATED YAW RATE SENSOR?. I WAS TOLD BY TELEPHONE THAT ?THE PREVIOUS REPAIR LASTED TWO YEARS?. ANY REASONABLE PERSON WOULD CONSIDER THAT THE POTENTIAL USEFUL LIFE OF THIS VEHICLE SHOULD EXCEED TWO ADDITIONAL YEARS. FURTHERMORE, THE FAILURE COULD POTENTIALLY REOCCUR IMMEDIATELY. AFTER BEING TOLD IT WAS TEST DRIVEN AND PRONOUNCED SAFE TO DRIVE I THINK THAT THIS IS AN UNSAFE SITUATION WAITING FOR ANOTHER EVENT TO OCCUR AND THAT AN ACCIDENT COULD RESULT FROM ANOTHER INSTANCE OF THE VSC SYSTEM FAILURE. THE PROBLEM WAS NOT PROPERLY LOCATED OR PROPERLY REPAIRED IN EACH OF THE TWO OCCURRENCES. A PROPER REPAIR OF THE VEHICLE AFTER THE FIRST EVENT WOULD HAVE PREVENTED THE SECOND. *TR

VARIATION IN BRAKE PRESSURE. SOMETIME BRAKES FEEL FINE AND BRAND NEW AND OTHER TIMES, BRAKE ALMOST GOES TO FLOOR. *TR

THE STEERING SENSOR ON THE ANTI-SKID SYSTEM SHORTED OUT CAUSING THE ANTI-LOCK BRAKES TO ENGAGE WHILE THE CAR WAS IN MOTION. THIS CAUSED A VERY DANGEROUS SITUATION. CAR HAD TO BE PULLED OF TO THE SIDE OF THE ROAD IN A HEAVY TRAFFIC ENVIRONMENT. CAR COULD NOT BE DRIVEN WITHOUT THE ANTI-LOCK BRAKES ENGAGING. CAR WAS TOWED TO THE TOYOTA DEALERSHIP. I ASKED THE DEALER TO DISCONNECT THE ANTI-SKID SYSTEM, BECAUSE THIS SYSTEM WAS MORE DANGEROUS THAN THE PROBLEM IT WAS TRYING TO ADDRESS. THE DEALER SAID THAT WAS NOT POSSIBLE AND IF THE STEERING SENSOR WAS NOT REPLACED, THE CAR WOULD NOT BE DRIVABLE. IF A SENSOR IN A CONTROL SYSTEM FAILS, IT SHOULD NOT CAUSE A DANGEROUS DRIVING SITUATION. IF A SENSOR FAILS, THE BRAKES SHOULD NOT ENGAGE, THE SYSTEM SHOULD JUST BECOME INOPERABLE. THE LOGIC IN THEIR CONTROL SYSTEM IS FAULTY AND THE COMPUTER SHOULD BE RE-PROGRAMMED TO ELIMINATE THE PROBLEM. TOYOTA MOTORS WAS INFORMED OF THE PROBLEM AND THEY CHOOSE TO IGNORE MY COMPLAIN. THE DEALERSHIP REPLACED THE STIRRING SENSOR FOR A RIDICULOUS PRICE AND THE CAR IS ABLE TO MOVE FORWARD AGAIN WITHOUT THE ANTI-LOCK BRAKES ENGAGING. MY WIFE IS AGAIN DRIVING A CAR WHICH IS INHERENTLY UNSAFE. WE ARE CONSIDERING SELLING THE CAR BECAUSE OF THE ONGOING SAFETY PROBLEMS. *TR

WHILE DRIVING HOME FROM WORK PULLED UP TO STOP LIGHT WITH MANY OTHER CARS THE LIGHT TURNED GREEN AND I GOT UP TO 20 MPH AND THE BRAKES KICKED ON SLOWING ME DOWN TO ALMOST A STOP, AND CREATING A LOUD NOISE. THE CAR BEHIND HIT ME, BUT DID NOT CAUSE ANY DAMAGE. HE SAID I HAD NO BRAKE LIGHTS. IT WILL ONLY GO 15 MPH BEFORE THE VEHICLE TRACTION CONTROL WENT ON AND STOPPED THE CAR. THERE WAS NO WARNING. THE DEALER SAID THERE WAS A TECHNICAL SERVICE BULLETIN IN FOR THE PROBLEM. I THINK TOYOTA SHOULD FIX THIS IN A RECALL BECAUSE IT COULD CAUSE SERIOUS INJURY , ESPECIALLY SINCE IT WAS THE TRACTION CONTROL SYSTEM WHICH ACTIVATED FOR NO REASON AND NO BRAKE LIGHTS WENT ON. *AK

THIS SITUATION HAS BEEN HAPPENING SINCE I BOUGHT MY HIGHLANDER IN NOVEMBER 2004. AFTER BACKING OUT OF MY DRIVEWAY OR MOVING IN REVERSE, THE FIRST TIME BRAKES ARE USED IN THE FORWARD OR DRIVE GEAR THERE IS A LOUD CLANK OR BANG FROM THE FRONT WHEEL BRAKES. I HAVE HAD THE DEALER CHECK THEM MORE THAN ONCE AND EVERY TIME I AM TOLD THAT IT IS NORMAL OR THAT THEY ARE UNABLE TO REPRODUCE. THIS IS NOT MY FIRST CAR EVER AND I'M SURE THAT I'VE NEVER HEARD THAT KIND OF NOISE IN MY BRAKES AFTER CHANGING GEARS. *NM

DT*: THE CONTACT STATED AFTER THE VEHICLE WAS PARKED FOR AN EXTENDED PERIOD OF TIME, WHILE BRAKE PRESSURE WAS APPLIED AT VARIOUS SPEEDS, THERE WAS AN INCREASED STOPPING DISTANCE. THE VEHICLE WAS INSPECTED BY A DEALER WHO DUPLICATED THE PROBLEM, YET WAS UNABLE TO REPAIR THE BRAKES DUE TO THE DESIGN. THE DEALER DETERMINED THE CONTACT NEEDED TO WARM UP THE ENGINE BEFORE DRIVING, BUT THE PROBLEM PERSISTED. THE MANUFACTURER WAS ALERTED. UPDATED 11/9/2006 - THE CONSUMER CONTACTED TOYOTA WHO SAID THE ARE STILL WORKING ON A FIX FOR THE PROBLEM. *NM

NO EVENTS LED UP TO THE FAILURE. WIFE DROVE CAR, BRAKE WARNING COMES UP ON DASHBOARD, SHE PULLED OVER. WIFE CALLED ME ON CELL. I THOUGHT IT W THE PARKING BRAKE. I TOLD HER TO MANIPULATE TO CLEAR THE WARNING TO NO AVAIL. THEN I TOLD HER TO OPEN THE HOOD TO LOOK AT THE BRAKE CYLINDER. THE BRAKE CYLINDER HAD DISCONNECTED FROM ITS HOLDER. A SINGLE PIN HOLDS IT IN PLACE. THIS PIN APPARENTLY BROKE CAUSING THE CYLINDER TO FALL OVER AND RELEASE THE BRAKE FLUID. THE CYLINDER WAS LAYNG OVER ON ITS SIDE DANGLING BY TWO WIRES. MY WIFE WAS ABOUT 80 MILES FROM HOME VISITING HER PARENTS. SHE THOUGHT SHE COULD DRIVE HOME SO IT COULD BE REPAIRED BY OUR DEALER, DAYTON TOYOTA IN DAYTON, NJ. I TOLD HER NOT TO DRIVE GIVEN THAT THERE WAS NO BRAKE FLUID. IF SHE HAD DRIVEN HER STOPPING DISTANCES WOULD HAVE BEEN A LOT LONGER. WE CONTACTED AAA THEN A LOCAL TOYOTA DEALER - STAR TOYOTA OF BAYSIDE, NY. THEY ARRANGED FOR A FLATBED TO BRING THE CAR TO THE DEALERSHIP. THE INCIDENT HAPPENED ON A SUNDAY SO IT STAYED AT A AAA SERVICE STATION OVERNIGHT. STAR TOYOTA NOTED THAT THEY WOULD WORK ON IT RIGHT AWAY SO MY WIFE COULD DRIVE HOME. THEY DIDN'T WORK ON IT UNTIL WEDNESDAY WHEN I HAD TO GO GET THE CAR. STAR REPLACED THE CYLINDER SUB ASSEMBLY, BLED THE SYSTEM AND REPLACED THE FLUID. MY CONCERN IS HOW MANY OTHER 2004 TOYOTA HIGHLANDERS ARE OUT THERE WITH THIS TYPE OF DEFECT. AS NOTED THERE WAS NO REASON FOR TEH FAILURE OF THE PIN HOLDING THE BRAKE FLUID CYLINDER. I THINK THERE SHOULD BE A WARNING TO DEALERS TO CHECK FOR THIS PROBLEM.

CONSUMER COMPLAINED ABOUT A BRAKE SYSTEM PROBLEM. CONSUMER TOOK VEHICLE TO THE DEALER ON SEVERAL OCCASIONS, AND DEALER PERFORMED REPAIRS. SHORTLY AFTER THE PROBLEM RECURRED. *AK THE CONSUMER FEELS THAT THE BRAKES ARE STILL NOT PERFORMING AS THEY SHOULD. THE TIRE WORE OUT PREMATURELY AT 24000 MILES. *NM

WHEN THE CONSUMER APPLIED THE BRAKES, THE PEDAL WENT TO THE FLOOR. THIS RESULTED IN THE CONSUMER'S VEHICLE REAR-ENDING ANOTHER VEHICLE. THE CONSUMER HAD THE VEHICLE TOWED TO THE DEALERSHIP FOR INSPECTION. *AK IT WAS DETERMINED THAT THE BRAKE PIVOT BRACKET HAD BENT, CAUSING THE BRAKES TO FAIL. *SC *JB