--- title: "2020-2025 Toyota Highlander Problems and Years to Avoid" description: "7 documented problems with the 2020-2025 Toyota Highlander, with symptoms, affected years, and typical repair costs. 3 of them are serious. 6 carry a recall or TSB number." url: "https://whichcarparts.com/cars/toyota/highlander/2020-2025/common-problems" updated: "2026-08-20" --- # 2020-2025 Toyota Highlander Common Problems and Years to Avoid 7 documented problems with the 2020-2025 Toyota Highlander, with symptoms, affected years, and typical repair costs. 3 of them are serious. 6 carry a recall or TSB number. **Quick answer**: We have 7 documented problems on record for the 2020-2025 Toyota Highlander, of which 3 are serious and 6 carry a recall or service bulletin. ## 2020-2025 Toyota Highlander recalls and service bulletins | Recall / TSB | Issue | Severity | | --- | --- | --- | | NHTSA 20V-162 | Stop-start ECU programming error (recall) | moderate | | Toyota fuel-fill TSBs; 2022 class action (no NHTSA recall) | Hybrid fuel tank won't fill to capacity | moderate | | NHTSA 23V-865 | Occupant Classification System sensor short (recall) | major | | NHTSA 23V-480; follow-up 25V-040 | Steering spiral cable. Driver airbag may deactivate (recall) | major | | NHTSA 25V-595 | Instrument cluster can fail to display speed and warnings (recall) | moderate | | NHTSA 23V-720 | Front lower bumper cover detaches after minor impacts (recall) | minor | Recall work is free at a franchised dealer regardless of the vehicle's age, mileage, or how many owners it has had. Check your VIN against the NHTSA database to see what is still outstanding. ## 8-speed transmission whine, shudder, and failures (2020-2022 V6) (major) The dominant NHTSA complaint category for this generation: 2020-2022 V6 cars with the UA80 8-speed report whining/grinding (front carrier pinion shafts on AWD units), low-speed shudder, harsh shifts, and in a minority of cases full transmission replacement. Toyota addressed symptoms with software and hardware TSBs; out-of-warranty replacements are expensive, so get any noise diagnosed while the 5 yr/60k powertrain warranty applies. Most affected: 2020-2022 (V6). Typical cost: Free under powertrain warranty; $4,000-$8,000+ for a transmission out of warranty. ## Stop-start ECU programming error (recall) (moderate) A programming error in the engine control unit could starve the engine of fuel when the stop-start system restarted it, causing hesitation or stall. Dealers reflash the ECU free of charge. Most affected: 2020. Typical cost: Free under recall (software update). Recall/TSB: NHTSA 20V-162. ## Hybrid fuel tank won't fill to capacity (moderate) Many 2020-2021 Highlander Hybrids can't take anywhere near the advertised 17.1 gallons, the pump clicks off around 12-13 gallons and the range estimate suffers. A tank-venting design issue prompted a class action; Toyota issued service bulletins and replaced fuel tank assemblies on some vehicles. If affected, document fills and work with the dealer under warranty. Most affected: 2020-2021 (hybrid). Typical cost: Free under warranty/TSB (fuel tank assembly replacement) where Toyota accepts the claim. Recall/TSB: Toyota fuel-fill TSBs; 2022 class action (no NHTSA recall). ## Occupant Classification System sensor short (recall) (major) A short circuit in the front passenger seat's OCS sensor can prevent the passenger airbag from deploying properly. Part of Toyota's ~1-million-vehicle December 2023 recall; dealers inspect and replace the sensor free. Most affected: 2020-2023. Typical cost: Free under recall. Recall/TSB: NHTSA 23V-865. ## Steering spiral cable. Driver airbag may deactivate (recall) (major) A defective spiral cable assembly in the steering column can break its connection and deactivate the driver's front airbag, lighting the airbag warning lamp. Toyota recalled 2023 Highlanders and later re-recalled some previously repaired vehicles. Free replacement. Most affected: 2023. Typical cost: Free under recall. Recall/TSB: NHTSA 23V-480; follow-up 25V-040. ## Instrument cluster can fail to display speed and warnings (recall) (moderate) On 2023-2024 models the instrument panel may fail to show vehicle speed, brake system, and tire pressure warnings. Fixed with a free dealer software update. Most affected: 2023-2024. Typical cost: Free under recall (software update). Recall/TSB: NHTSA 25V-595. ## Front lower bumper cover detaches after minor impacts (recall) (minor) A minor parking-lot bump can leave the front lower bumper cover loose or falling off entirely, a road hazard. Toyota recalled 2020-2023 Highlanders to improve the bumper cover retention free of charge. Most affected: 2020-2023. Typical cost: Free under recall. Recall/TSB: NHTSA 23V-720. Problems listed here are compiled from NHTSA complaints, recalls, technical service bulletins, and widely documented owner reports for the 2020-2025 Toyota Highlander. Not every vehicle will experience these issues. ## Which Toyota Highlander model years does this cover? These problems and recalls specifications apply to every Toyota Highlander built from 2020 through 2025, the XU70 (4th generation), mid-size 3-row crossover suv (tnga-k platform). Nothing in this specification changes between those model years. - [2020 Highlander](https://whichcarparts.com/cars/toyota/highlander/2020) - [2021 Highlander](https://whichcarparts.com/cars/toyota/highlander/2021) - [2022 Highlander](https://whichcarparts.com/cars/toyota/highlander/2022) - [2023 Highlander](https://whichcarparts.com/cars/toyota/highlander/2023) - [2024 Highlander](https://whichcarparts.com/cars/toyota/highlander/2024) - [2025 Highlander](https://whichcarparts.com/cars/toyota/highlander/2025) ## What changed during the 2020-2025 Toyota Highlander | Years | What changed | | --- | --- | | 2020 | Generation launch on TNGA-K. Towing: 5,000 lbs V6 with tow package, 3,500 lbs hybrid. Hybrid drops the V6 for a 2.5L four (243 hp net) and adds a FWD option | | 2021 | XSE trim added | | 2022 | Bronze Edition (hybrid) added; final V6 year alongside 2020-2022 transmission complaint cluster | | 2023 | 2.4L turbo (T24A-FTS, 265 hp) replaces the V6; larger 12.3-in touchscreen/cluster available; towing stays 5,000 lbs with tow package | | 2024-2025 | Carryover years; the larger Grand Highlander is a separate model. 2023-2024 cars are in the 25V-595 cluster-software recall population | ## 2020-2025 Toyota Highlander problems and recalls: common questions ### What are the most common problems with the 2020-2025 Toyota Highlander? The recurring ones are: 8-speed transmission whine, shudder, and failures (2020-2022 v6); stop-start ecu programming error (recall); hybrid fuel tank won't fill to capacity; occupant classification system sensor short (recall); steering spiral cable. driver airbag may deactivate (recall). Each is detailed above with symptoms, affected years, and typical cost. ### Which 2020-2025 Toyota Highlander years should you avoid? The years to be most careful with are those affected by 8-speed transmission whine, shudder, and failures (2020-2022 v6) (2020-2022 (V6)) and occupant classification system sensor short (recall) (2020-2023) and steering spiral cable. driver airbag may deactivate (recall) (2023). A documented problem is not automatically a reason to walk away. Service records showing the repair was done change the picture entirely. ### Are there recalls on the 2020-2025 Toyota Highlander? 6 of the issues listed carry a recall or technical service bulletin: NHTSA 20V-162 (stop-start ecu programming error (recall)), Toyota fuel-fill TSBs; 2022 class action (no NHTSA recall) (hybrid fuel tank won't fill to capacity), NHTSA 23V-865 (occupant classification system sensor short (recall)), NHTSA 23V-480; follow-up 25V-040 (steering spiral cable. driver airbag may deactivate (recall)), NHTSA 25V-595 (instrument cluster can fail to display speed and warnings (recall)), NHTSA 23V-720 (front lower bumper cover detaches after minor impacts (recall)). Recall work is free at a franchised dealer regardless of age or mileage. Check your VIN on the NHTSA site to see what is outstanding. ### How much do 2020-2025 Toyota Highlander repairs typically cost? Typical figures for the issues above: 8-speed transmission whine, shudder, and failures (2020-2022 v6), Free under powertrain warranty; $4,000-$8,000+ for a transmission out of warranty; stop-start ecu programming error (recall), Free under recall (software update); hybrid fuel tank won't fill to capacity, Free under warranty/TSB (fuel tank assembly replacement) where Toyota accepts the claim; occupant classification system sensor short (recall), Free under recall. ## Sources - [Toyota technical data, Highlander XU70 fluids & capacities (toyota-club.net)](https://toyota-club.net/files/techdata/ttx/highlander_70u.htm) - [Toyota Owners, 2021 Highlander Hybrid owner's manual, 12-volt battery location](https://www.toyota.com/owners/warranty-owners-manuals/digital/article/highlander-hv/2021/om0e143u/ch06se030405/) - [Toyota TrueStart battery application chart, H6 EFB (gas) / H5 LN2 (hybrid)](https://www.toyotapartsandservice.com/wp-content/uploads/2022/11/03_Batteries2022_hi.pdf) - [Lakeland Toyota parts, 17801-F0050 engine air filter, 2021/2023 Highlander fitment](https://parts.lakelandtoyota.com/p/toyota_2023_HIGHLANDER/Engine-Air-Filter/14760743/17801F0050.html) - [Woburn Toyota parts, 04152-YZZA1 oil filter element fitment for the 2.4L turbo](https://parts.woburntoyota.com/p/Toyota_2025_GRAND-HIGHLANDER-24L-AT-AWD-Limited-Sport-Utility/Engine-Oil-Filter-Element/49507508/04152YZZA1.html) - [Lakeland Toyota parts, 90919-A1008 spark plug (2.4L turbo)](https://toyotaparts.lakelandtoyota.com/oem-parts/toyota-spark-plug-90919a1008) - [AMSOIL lookup, 2023 Highlander 2.4L T24A-FTS: 0W-20, 5.6 qt](https://www.amsoil.com/lookup/auto-and-light-truck/2023/toyota/highlander/2-4l-4-cyl-engine-code-t24a-fts-g-turbo/) - [NHTSA recall 23V-865, occupant classification sensor](https://www.nhtsa.gov/recalls?nhtsaId=23V865000) - [NHTSA recall 25V-595, instrument cluster display](https://www.nhtsa.gov/recalls?nhtsaId=25V595000) - [ClassAction.org, 2020-2021 Highlander Hybrid fuel tank fill issue](https://www.classaction.org/news/venting-issue-prevents-2020-2021-toyota-highlander-hybrid-fuel-tank-from-being-filled-to-capacity-class-action-claims) - [The Weekly Driver, 2020-2025 Highlander NHTSA complaint analysis (transmission cluster)](https://theweeklydriver.com/reliability/toyota/highlander/2020-2025/) - [Wheel-Size.com, 2023 Toyota Highlander OE fitments](https://www.wheel-size.com/size/toyota/highlander/2023/) - [fueleconomy.gov, 2021 / 2023 Highlander EPA ratings](https://www.fueleconomy.gov/feg/bymodel/2023_Toyota_Highlander.shtml) ## Other Toyota Highlander generations - [2014-2019 Toyota Highlander problems and recalls](https://whichcarparts.com/cars/toyota/highlander/2014-2019/common-problems) - [2012-2013 Toyota Highlander problems and recalls](https://whichcarparts.com/cars/toyota/highlander/2012-2013/common-problems) Or [compare all generations](https://whichcarparts.com/cars/toyota/highlander/common-problems). ## More for the 2020-2025 Toyota Highlander - [Oil & filter](https://whichcarparts.com/cars/toyota/highlander/2020-2025/oil) - [Battery](https://whichcarparts.com/cars/toyota/highlander/2020-2025/battery) - [Tires & wheels](https://whichcarparts.com/cars/toyota/highlander/2020-2025/tires) - [Wiper blades](https://whichcarparts.com/cars/toyota/highlander/2020-2025/wipers) - [Air & cabin filters](https://whichcarparts.com/cars/toyota/highlander/2020-2025/filters) - [Bulbs](https://whichcarparts.com/cars/toyota/highlander/2020-2025/bulbs) - [Brakes](https://whichcarparts.com/cars/toyota/highlander/2020-2025/brakes) - [Fluids](https://whichcarparts.com/cars/toyota/highlander/2020-2025/fluids) - [Service schedule](https://whichcarparts.com/cars/toyota/highlander/2020-2025/service-schedule) - [Oil light reset](https://whichcarparts.com/cars/toyota/highlander/2020-2025/oil-reset) - [Key fob battery](https://whichcarparts.com/cars/toyota/highlander/2020-2025/key-fob-battery) - [Specs](https://whichcarparts.com/cars/toyota/highlander/2020-2025/specs) Specifications vary with engine option, production date, and market.