2020 Toyota Highlander Body & Structure Problems

While driving on a 75 MPH highway, the lower bumper cover, windscreen, and interior wheel well components spontaneously detached from the vehicle and got stuck under the car. There were no warming lamps, messages, or other symptoms; the vehicle was driving fine before the detachment. The vehicle has never been in a collision and had no visible damage to the bumper prior to the incident. The detachment was very quick and could have caused an accident, as it was quite physically jarring; additionally, the components got between the vehicle and the highway which caused them to smoke/burn as I tried to quickly slow and pull into the shoulder. A prior recall (#23TB12 / 23TA12) was for a very similar situation. The dealership had allegedly performed the recall fix in March 2025. When I took the vehicle back to the dealership, they said this was independent of the recall. The dealership is unwilling to cover the repair, as they have said that the bumper shows signs of impact. The vehicle bumper has never been impacted. The dealer said there were very minor stress cracks in the paint; when I asked if these could have been from the bumper cover rapidly detaching, they said it was possible but would still not cover the repair.

I know there is a recall for my 2020 Highlander. My VIN isn't listed. The front bumper is coming off and can't be pushed back in.

We own a 2020 Toyota Highlander, and both of the exterior door handles for the backseat have broken. The first in Jan 2025 and the second a few days ago. When the first was repaired (a different door) I was told this happens often on Toyota doors and is to be expected. If this is true why are stronger components not being used in manufacturing? The first doorhandle was replaced totaling $370 and now we are going to have to replace the second. It is disheartening to know that you can purchase a car that is supposed to be so safe, but if something were to happen I might not have a way to open the door to get to my children in the back seat.

Went to close the right rear passenger door and heard splashing. Door is leaking from somewhere and running down to the bottom of the door filling it with water on the inside.

In reference to NHTSA Recall no. 23V-720 I have made several attempts to have the recall remedied at a certified dealer, dealership is 4hrs away, round trip. On 3 separate occasions I made appointments online for maintenance plus recall. In between 2nd and 3rd remedy attempt lower bumper detached on the highway into traffic. My own vehicle ran it over, several cars swerved on the roadway to avoid the obstacle, some successful and some hit it head on sending it across multiple lanes, it was lastly struck by a semi truck and unrecoverable. On the 3rd attempted I questioned why the recall was not being completed. I was told recalls need to be on a separate appointment. 4th attempt was for the only recall and was turned away because of damage on the upper bumper. Damage was chipped paint and a slight crease near the fog lamp hole. Damage was caused by the upper bumper flapping in the wind while driving since it was no longer braced by lower bumper. I was provided a flow chart by the maintenance manager stating that I needed to repair my bumper before the safety recall could be performed. I showed my recall notice that stated if damage was found on the upper bumper, both upper and lower would be replaced. I asked if my vehicle was going to be evaluated and was told no. A few days later I received a voicemail(missed the call) that my parts had arrived and an appointment had been made for me. I did not ask them to order the parts, I did not plan on returning to them because of their flippant attitude towards my safety. I felt obligated and trapped to return to them since they ordered the parts. I replaced my bumper but did not paint it yet. I figured since the chipped paint was a deciding factor to my safety it would be better not to have it in case other paint damage occurred. (why does paint matter on a safety recall?) Went to 5th attempt and was turned away because my upper bumper was unpainted. I have made appt with new dealer. This is not a reasonable time-frame.

While driving on a highway, with little traffic around, our sunroof exploded, sending shards of glass down. It produced a sound of a gunshot and quite possibly could have resulted in such a distraction to cause a wreck. The vehicle has not been inspected but insurance agents has been contacted. There were no warnings at all.

The contact owns a 2020 Toyota Highlander. The contact stated while driving at approximately 65 MPH, the front lower bumper cover detached from the vehicle, causing debris to scatter onto the highway, while the damaged bumper cover was dragged underneath the vehicle. During the failure, the vehicle sustained excessive front-end damage, and damages to the undercarriage and fender liners. The vehicle was taken to the local dealer who confirmed that the failure was related to NHTSA Campaign Number: 23V720000 (Structure). The contact stated that the vehicle had experienced the failure listed in the recall. The vehicle was not yet repaired. The manufacturer was notified of the failure. The failure mileage was 51,260.

The contact owns a 2020 Toyota Highlander. The contact received notification of NHTSA Campaign Number: 23V720000 (Structure). The contact stated while driving at approximately 40 MPH, the front bumper detached from the vehicle. The vehicle was taken to a dealer where it was diagnosed that the upper and lower bumper, underpinning, wheel well assembly covers, and other unknown parts needed to be replaced. The vehicle was not repaired. The manufacturer was notified of the failure. The failure mileage was approximately 89,000.

The contact owns a 2020 Toyota Highlander. The contact received notification of NHTSA Campaign Number: 23V720000 (Structure), however, the part to repair was unavailable. The contact stated that the manufacturer exceeded a reasonable time to remedy the recall repair. The manufacturer was made aware of the issue. The contact had not experienced a failure. Parts distribution disconnect.

We were driving at around 70 mph on lane #3 on [XXX] near Auburn CA at around [XXX] on [XXX] with 2 passengers and some baggage in the trunk. No baggage were on the roof rack. Traffic was light and no vehicle was directly ahead of us at the time. Weather was cloudy. Suddenly we heard a loud bang above us, like a gun going off. I opened the sunroof cover and found the sunroof glass shattered. After exiting the freeway and parking, we found only the sunroof glass was damaged. The glass was shattered but still intact. There was no damage to the roof or roof racks. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

The contact owns a 2020 Toyota Highlander. The contact stated while driving approximately 50 MHP, the contact's husband became aware that there was unknown part had loosened on the front of the vehicle. The contact pulled over to the side of the road and upon inspecting the vehicle, the contact became aware that the front bumper assembly was detaching. The vehicle was taken to an independent mechanic however, the vehicle was not repaired due to the cost. The contact then received notification of NHTSA Campaign Number: 23V720000 (Structure) however, the part to do the recall repair was not yet available. The local dealer was contacted. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The manufacturer was not made aware of the issue. The failure mileage was approximately 30,000. Parts distribution disconnect.

The contact owns a 2020 Toyota Highlander. The contact received notification of NHTSA Campaign Number: 23V720000 (Structure) however, the part to do the recall repair was not yet available. The local dealer was made aware of the issue and confirmed that parts were not yet available. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The manufacturer was made aware of the issue. The contact had not experienced a failure. VIN tool confirms parts not available.

The contact owns a 2020 Toyota Highlander. The contact stated while driving 60-65 MPH and changing lanes, the front lower bumper cover suddenly separated from the vehicle. The contact pulled over to the side of the road. The vehicle was taken to the dealer, where the front lower bumper cover assembly was replaced. The vehicle was repaired. The contact later received notification of NHTSA Campaign Number: 23V72000 (Structure) which the contact related to the failure. The manufacturer was contacted for reimbursement, but the manufacturer denied reimbursement. The failure mileage was unknown.

About once or twice a week as I'm slowly braking to make a turn or stop, the car will surge forward. I have to depress the brake harder, and it does stop or keep slowing. I'm very concerned that if this happens as I'm stopping at a cross walk, someone could be hurt. I took it to the dealer who couldn't replicate it, so said it wasn't a safety issue. There are lots of forums that describe this with highlanders. My partner can feel it happen too. I'm not sure if it's the braking system or engine. My guess is engine because it seems to be a power surge. It's inconsistent, and happens in all kinds of weather, hot/cold, dry/wet. No warning lights, or messages. Happens a lot, but I'm using the example of earlier this week. You're welcome to inspect if you want. It is a hybrid and one of my friends said it might be switching systems, but our other car is also a hybrid and doesn't have anything like this happening.

The contact owns a 2020 Toyota Highlander. The contact received notification of NHTSA Campaign Number: 23V720000 (Structure); however, the part to do the recall repair was not yet available. The contact stated that the front lower bumper cover had detached on the front passenger's side and was swinging while driving. The vehicle was taken to the dealer, who informed the contact that the vehicle needed to be repaired at an auto body collision shop due to a crack on the front lower bumper cover, prior to the recall repair. The contact stated that the dealer failed to honor the recall repair because the recall repair involved repairing or replacing the upper and lower front bumper covers as necessary, free of charge. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The manufacturer was made aware of the failure and a case was opened; however, no further assistance was provided. The failure mileage was approximately 40,000. Parts distribution disconnect.

The contact owns a 2020 Toyota Highlander. The contact was informed by an independent mechanic that the front bumper had begun to detach from the vehicle on the driver's and passenger’s side ends of the vehicle. The vehicle was taken to a dealer but was later referred to an independent body shop for service. The contact then discovered that the vehicle was included in NHTSA Campaign Number: 23V720000 (Structure) however, the part to do the recall repair was not yet available. The local dealer was made aware of the issue and confirmed that parts were not yet available. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The failure mileage was unknown. VIN tool confirms parts not available.

Driving at highway speeds of 75 mph (posted speed), front bumper fell off of car. Outside temperature was 107 degrees. Bumper was lodged under car and all insulation peeled off of wheels. Had to pull all parts from under car and around wheel openings and was able to continue to destination. No accident occurred as the result of this as I was able to safely pull over to side of road.

The contact's wife owns a 2020 Toyota Highlander. The contact stated while the vehicle was parked, his wife noticed that the front passenger's side carpeting was extremely wet. Upon investigating the failure, both the contact and his wife noticed that the carpeting underneath was extremely soaked. The contact stated that both he and his wife used towels to soak up the water. The vehicle was taken to an independent mechanic where it was diagnosed that the HVAC evaporator drain hose was clogged, which caused water to leak into the front passenger's side of the vehicle. The independent mechanic informed the contact that the failure was related to Toyota Technical Service Bulletin Number: 0080-19 (HVAC Evaporator Drain Hose Clogged Due to Insect Intrusion) and referred the contact to the dealer for the repair. The dealer and the manufacturer were notified of the failure and informed the contact that the repair could not be covered under warranty. The vehicle was not repaired. The failure mileage was approximately 12,300.

While driving on the freeway, with no prior damage, the front bumper came lose and dragged under vehicle.

See attached document for complaint.