2006 Toyota Highlander Hybrid Problems, Recalls & Reliability

1. NHTSA 13V396000Sep 4, 2013Fuel System133,081 vehicles

   Hybrid propulsion system: inverter

   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.

   Risk: 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.

2. NHTSA 11V539000Nov 9, 2011Engine420,326 vehicles

   Engine and engine cooling

   Toyota is recalling certain model year 2004 avalon vehicles; 2004 and 2005 camry, camry solara, highlander, and sienna vehicles, 2006 highlander hybrid; 2004 and 2005 lexus es330 and rx330; and 2006 lexus rx400h vehicles manufactured from june 1, 2004 through march 31, 2005, equipped with the 1mz-fe or 3mz-fe engine. The amount of adhesive agent applied between the outer ring and the torsional rubber damper (inner ring) in the crankshaft pulley may be inadequate. If the adhesive is insufficient, there is a possibility that the outer ring may become misaligned and it may not properly rotate with the inner ring, causing noise and/or illumination of the battery discharge indicator light.

   Risk: In some cases, the belt for the power steering pump may become detached from the pulley which could result in a loss of power steering and a sudden increase in steering effort, increasing the risk of a crash.

   Remedy: Toyota will notify owners, and dealers will check the crankshaft pulley to identify whether it was produced by the u.s. Supplier. If so, the dealer will replace the pulley with a new one at no charge. The safety recall is expected to begin during early january 2012. Owners may contact toyota at 1-800-331-4331.

3. NHTSA 11V342000Jun 29, 2011Electrical System82,273 vehicles

   Electrical system

   Toyota is recalling certain model year 2006-2007 highlander hybrid and lexus rx400h passenger cars manufactured from february 16, 2005, through august 30, 2006. A module inside the inverter module may contain inadequately soldered transistors that during high-load driving, may be damaged by heat caused by the large current. 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.

   Risk: 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/lexus mailed an interim owner notification on july 19, 2011 to advise owners of this recall and the fact that they will receive a future notice when parts become available to complete repairs. Toyota dealers will inspect the hybrid inverter production number to determine whether the inverter contains suspect transistors and replace the module free of charge. Owners may contact toyota at 1-800-331-4331.

See all 6 recalls for the 2006 Toyota Highlander Hybrid →