Some 2020 – 2023 model year Highlander and Highlander Hybrid vehicles may exhibit a condition in which the Power Back Door (PBD) will not open or close and/or stops moving while opening or closing. A modified PBD unit assembly is available to address these conditions.
full bulletin at NHTSA ↗2020 Toyota Highlander body problems
moderate 25 complaints filed with NHTSA · avg repair $1,500 · see body across all vehicles →
Failure mileage
Complaints
25
Recalls
0
Avg fix
$1,500
1crash
What stands out
Owners have filed 25 body complaints with NHTSA against this vehicle, but no formal recall covers the issue — the federal record reflects what manufacturers have admitted, not everything owners are reporting.
Is there a fix? Manufacturer service bulletins
The manufacturer has issued service bulletins covering body on this vehicle — documented repair instructions, service campaigns, or warranty extensions sent to dealers. A TSB isn't a recall (it's not a free safety remedy), but it's the manufacturer acknowledging the issue and how to fix it.
Acid rain results from rainwater or other airborne moisture that become acidic due to industrial chemical impurities in the atmosphere. If these acidic compounds settle on an exposed vehicle, especially the horizontal areas such as the hood, roof, and decklid, significant damage to the painted surfaces can occur. Acid rain damage can typically be identified on vehicles by the presence of stains on the paint surface that resemble hard water spots. Unlike water spots however, acid rain damage cannot be removed by regular washing procedures. Also, because acid rain can etch and soften the paint, normal buffing or polishing repair procedures should not be attempted. This can cause further damage
full bulletin at NHTSA ↗To prevent brake rotor rust from forming during transportation and storage, wheel film will be used instead of a cardboard type of anti-rust cover. The purpose of the wheel film is to shield the disc brake rotor from weather elements and initial rust before the vehicle is delivered to the customer. Consequently, the film should remain on the wheel for as long as possible.
full bulletin at NHTSA ↗The condition known as acid rain is caused by airborne chemicals or particles in the atmosphere, which mix with rainwater, nighttime dew, or high humidity to form acidic compounds. If these contaminants settle and remain on a painted vehicle surface, especially the horizonal areas of the hood, roof, and decklid, significant damage can occur. This damage is the result of actual etching of the paint and appears as pitting or water spots. As acid rain droplets on the vehicle surface evaporate, the concentration strength of the acid increases, causing deeper and more rapid damage. This evaporation and corrosive action also occur more rapidly on dark colored cars as direct sun heat increases. It
full bulletin at NHTSA ↗Toyota vehicles are currently protected with RapgardTM protective film designed to protect the horizontal painted surfaces. This material protects from acid rain, environmental fallout, and rail contamination. Follow the Removal Procedure in this bulletin to remove the RapgardTM protective film within 90 days from initial application.
full bulletin at NHTSA ↗Source: NHTSA manufacturer communications. Bring the bulletin number to your dealer or shop.
The failure pattern owners describe
The bumper detachment problem is widespread and dangerous. Owners describe the front lower bumper separating while driving at highway speeds (40–75 mph), sometimes dragging underneath the vehicle and causing additional undercarriage damage. One owner had the bumper detach on the freeway, run him over, scatter debris that struck multiple vehicles, and eventually get hit by a semi truck. Recall 23V720000 exists to replace both upper and lower bumper assemblies, but dealers have consistently refused to perform the work—citing unavailable parts, pre-existing scratches or cracks, or damaged clips. Multiple owners were turned away repeatedly despite having recall notices. One dealer even ordered parts without authorization and then demanded the owner return for the repair after installing an unpainted bumper, creating a catch-22 over paint condition on a safety recall.
Sunroof explosions are another serious issue. At least six owners report the panoramic sunroof spontaneously shattering or exploding while driving on freeways—producing a sound like a gunshot with no prior warning, impact, or symptom. One failure occurred at just 4,000 miles. Toyota and its dealers have refused warranty coverage, instead blaming the owners for phantom chips or impacts and shifting repair costs to insurance. One owner was stuck with $1,900 in car rental expenses Toyota refused to pay.
Water leaks from clogged HVAC drains and door panels, rear door handles breaking within weeks of each other, unexpected engine surges during braking, and vibration at highway speeds round out the complaints. No owner reported successful recall repairs.
Same Toyota Highlander body reports on nearby years: 2019 · 2021 · 2022 · 2023
Failure modes owners describe
Front bumper assembly detachment
Lower bumper cover separates from attachment points and either detaches completely or hangs while driving. Several owners reported bumper dragging underneath the vehicle after separation, causing additional undercarriage and component damage. Some instances involved partial detachment with upper bumper also becoming compromised.
When: Varied mileage: 7,000 to 89,000 miles; failure during normal highway driving at speeds 40–75 mph
Symptoms owners cite: Bumper hanging or swinging during driving; Loud or abnormal noises from front of vehicle; Visual evidence of detached or loose bumper assembly; Debris scattered onto roadway after separation
Repairs/costs cited: Dealers informed owners that upper and lower bumper covers, underpinning, wheel well assembly covers, and other parts required replacement. Some owners incurred out-of-pocket costs at body shops before recall parts became available. One owner paid for bumper replacement but delayed painting due to dealer confusion about paint condition affecting safety recall eligibility.
Recalls/TSBs owners mention: NHTSA Campaign Number 23V720000 (Structure) covers this issue. Owners repeatedly reported that dealers refused to perform recall repairs citing missing parts (distribution delays), pre-existing damage on bumpers, or damaged bumper clips. Multiple dealers denied recall eligibility or demanded owners repair damage first. Toyota's parts distribution system created significant delays; several complaints note manufacturers exceeded reasonable timeframes for remedy.
Panoramic sunroof spontaneous failure (explosion/shattering)
Sunroof glass spontaneously exploded or shattered while vehicle was in motion on freeways at highway speeds, producing a loud sound likened to a gunshot. One complaint noted the remaining glass formed shards pointed upward like a volcano. No evidence of prior impact, chip, or defect triggering the failure.
When: Varied mileage including very low (4,000 miles); failure on highway/freeway at speeds 50–75 mph with no traffic incidents or external damage preceding event
Symptoms owners cite: Loud explosive sound (gunshot-like); Glass shattering or exploding outward; Flying glass shards into cabin; No prior warning messages or symptoms; No visible damage to roof or roof racks
Repairs/costs cited: Dealers and Toyota initially blamed owners, claiming chip or prior impact (false per owners). Replacement sunroof assembly, glass, and cleanup estimated at $2,410 plus labor. One owner's insurance deductible was $500; Toyota later paid deductible as goodwill but refused to cover rental car costs ($1,900).
Recalls/TSBs owners mention: Toyota Corporate refused to acknowledge manufacturing defect and offered Goodwill Settlement Agreements to preclude further action. Dealers billed insurance companies. Toyota refused to cover rental car expenses or acknowledge liability. No recall identified.
HVAC evaporator drain hose clogged (water intrusion)
HVAC evaporator drain hose became clogged, causing water to accumulate and leak into the vehicle interior. Front passenger-side carpeting was soaked and the underpad was extremely wet.
When: Approximately 12,300 miles
Symptoms owners cite: Extremely wet carpeting on front passenger side; Soaked underpad; Water pooling visible during parking
Repairs/costs cited: Independent mechanic diagnosed clogged drain hose; owner used towels to soak up water. Repair not completed at dealer.
Recalls/TSBs owners mention: Toyota Technical Service Bulletin 0080-19 references this failure (HVAC Evaporator Drain Hose Clogged Due to Insect Intrusion). Dealer informed owner repair was not covered under warranty.
Rear door handle breakage
Exterior door handles on rear passenger doors broke, rendering doors difficult or impossible to open from outside. Owner reported both rear door handles failed within weeks of each other.
When: First handle failure January 2025; second failure a few days later
Symptoms owners cite: Rear door handle broken or inoperable; Door difficult to open from outside
Repairs/costs cited: First door handle replacement cost $370. Dealer stated this failure is common on Toyota doors and to be expected. Second replacement also required.
Recalls/TSBs owners mention: No recall. Dealer acknowledged failure is frequent but presented it as expected wear.
Unexpected engine/hybrid system surge during braking (braking feel issue)
Vehicle surges forward during light braking when making turns or slowing to a stop, requiring driver to depress brake harder to maintain control. Occurs once or twice weekly, is inconsistent, and happens in all weather conditions. Owner suspects either a braking system issue or a power surge from the engine/hybrid system switching between propulsion sources.
When: Intermittent; no specific mileage noted
Symptoms owners cite: Vehicle surges forward during light braking; Loss of braking authority requiring harder brake pressure; Inconsistent occurrence (once or twice weekly); Happens in all weather conditions (hot, cold, wet, dry); No warning lights or messages; Occurs in hybrid and non-hybrid driving modes
Repairs/costs cited: Dealer could not replicate issue and dismissed as non-safety concern. Owner reports other hybrid vehicle does not exhibit this behavior.
Recalls/TSBs owners mention: No action taken. Owner notes forums document similar complaints on Highlanders.
Poor rear visibility due to mirror and window design
Large exterior mirrors positioned high relative to the passenger-side window create a blind spot that obscures traffic on the passenger side. Owner with a low seat position (due to back pain) collided with vehicle in passenger-side blind spot; mirrors were tall and prominent, blocking sightline to approaching traffic.
When: Incident August 4, 2021
Symptoms owners cite: Unable to see traffic on passenger side despite checking mirror; Large blind spot on passenger side; Mirror size and height contribute to obstruction of passenger-side window view
Repairs/costs cited: Owner's vehicle was totaled. Airbags did not deploy. No injuries.
Recalls/TSBs owners mention: No recall identified. Issue documented in online forums as affecting multiple owners.
Door panel water intrusion
Rear passenger door leaking water from an unknown source, with water running down the interior of the door panel and pooling at the bottom.
When: Timing not specified
Symptoms owners cite: Water splashing sound when closing door; Water inside door panel; Water pooling at base of door
Repairs/costs cited: Not repaired; issue reported to NHTSA.
Recalls/TSBs owners mention: No information provided.
Dashboard/mirror vibration at highway speeds
At highway speeds around 70 mph, vehicle develops a wobble with driver-side mirror visibly shaking. Owner had vehicle less than one year and reported to dealership.
When: Less than one year of ownership
Symptoms owners cite: Vehicle wobble at highway speeds; Driver-side mirror shaking; Issue occurs around 70 mph
Repairs/costs cited: Not repaired.
Recalls/TSBs owners mention: Dealership stated it could be a future recall but did not address the problem.
Synthesized from 25 NHTSA owner complaints — unverified consumer allegations, summarized for patterns. The verbatim filings appear below.
What owners are reporting 1 most recent
The contact owns a 2020 Toyota Highlander. The contact received notification of NHTSA Campaign Number: 23V72000 (Structure). The vehicle was taken to the dealer; however, the contact was informed that the recall could not be performed due to a damaged bumper clip. In addition, the contact stated that the vehicle was taken to the dealer several times, however the recall repair was not performed.…
Had body trouble with your 2020 Toyota Highlander?
File a complaint with NHTSA → It's free, official, and how every report above got here — owner filings are the federal safety record this page is built on.
Common questions
How serious is the body problem on the 2020 Toyota Highlander?
It's a documented issue but not catastrophic. 25 complaints have been filed. Repairs average $1,500 and most owners catch it before it causes a breakdown.
At what mileage does the body typically fail?
Across the 8 complaints that reported odometer mileage, most body failures cluster between 7,000 and 51,260 miles, with the median around 30,000. A quarter of owners report trouble before 7,000; a quarter make it past 51,260. Maintenance history matters more than the odometer alone — this is the reported failure window, not a guarantee.
What does it cost to fix?
Independent shops typically charge around $1,500 for body repairs on this vehicle. Dealer pricing tends to run 20-40% higher. The exact figure depends on the specific failure mode, parts availability, and your local labor rates. If you're outside factory warranty, an extended service contract often covers this category.
Are there any recalls related to body?
No active recalls currently cover body issues on this vehicle. The complaints filed represent owner-reported failures that haven't risen to the level of a manufacturer-issued recall — but they're still worth knowing about before you buy or budget for repairs.
Related
Complaint and recall data sourced from the National Highway Traffic Safety Administration (NHTSA)
public records database. Verify the raw federal record at
nhtsa.gov/vehicle/2020/Toyota/Highlander.
Severity ratings are derived from reported crashes, fires, injuries, and fatalities. Repair cost estimates are
independent-shop national averages and may differ in your area. Some links on this page are affiliate links.