Some 2020 – 2026 model year Highlander and Highlander Hybrid vehicles may exhibit a water leak from the roof rack attachment clips. This may be caused by the sealant in the roof channel obstructing the proper seating position for the clip gasket.
full bulletin at NHTSA ↗2021 Toyota Highlander body problems
severe Owners of the 2021 Toyota Highlander have filed 40 NHTSA complaints about the body at roughly $1,500 to repair (U.S. federal records, as of July 2026). Source: NHTSA Office of Defects Investigation. See body across all vehicles →
Complaints
40
Recalls
0
Avg fix
$1,500
| Model year | body complaints |
|---|---|
| 2017 Highlander | 6 |
| 2018 Highlander | 8 |
| 2019 Highlander | 11 |
| 2020 Highlander | 27 |
| 2021 Highlander (this page) | 40 |
| 2022 Highlander | 38 |
| 2023 Highlander | 29 |
1crash
3injuries
What stands out
Of the 19 model years of Toyota Highlander we track for body problems, this one carries the most owner complaints on file — 40.
Owners have filed 40 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.
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 ↗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 ↗Source: NHTSA manufacturer communications. Bring the bulletin number to your dealer or shop.
The failure pattern owners describe
The 2021 Highlander exhibits multiple body-related defects affecting safety and structural integrity. The driver-side mirror vibrates excessively at highway speeds and even at idle, causing blurred reflections that impair lane-change and merge maneuvers. Dealerships confirm the vibration is present across all Highlanders but claim it's normal design behavior—Toyota issued a service bulletin for RAV4 mirrors but has not done so for Highlander.
Front bumper clips fail repeatedly, causing the lower and upper bumper covers to detach while driving, sometimes at highway speeds with minimal or no impact. NHTSA recall 23V720000 addresses this, but replacement parts remain unavailable months after the recall issued, leaving owners stranded with known defects.
Water intrusion from failed roof rack seals and A-pillar gaskets allows rainwater into door panels, headliner areas, and floor spaces, promoting black mold and mildew that owners report causes respiratory symptoms. Toyota issued Service Bulletin T-SB-0040-24 in April 2024 but dealers refuse to perform the repair.
Sunroof glass spontaneously shatters under normal driving conditions without external impact, ejecting glass fragments at highway speeds. Windshields crack repeatedly under normal use. Door panels and windows bow outward from structural defects. Excessive wind noise inside the cabin reaches 79 dB at 55 mph but dealers claim Toyota's acceptable limit is 100 dB. Liftgate motors malfunction intermittently, especially in cold weather, and power door components are the subject of an ongoing class action lawsuit.
Same Toyota Highlander body reports on nearby years: 2019 · 2020 · 2022 · 2023
Failure modes owners describe
Driver-side mirror vibration
Mirror vibrates excessively at highway speeds and even at idle, causing blurry reflections and safety concerns during lane changes and merging. Occurs immediately after factory mirror replacement. Dealer acknowledges issue is present across all Highlanders but claims it is normal design behavior. Toyota has issued TSB for RAV4 mirrors but none for Highlander.
When: Since purchase; first reported after 2+ years of ownership; replacement performed May 2023
Symptoms owners cite: vibration in driver-side mirror at speeds above 40-50 mph; mirror vibration at idle; blurry mirror image; vibration during lower speeds after replacement; difficulty concentrating while driving due to mirror movement
Repairs/costs cited: Part Number: 879400E351 replaced; vibrations persisted post-repair
Recalls/TSBs owners mention: Dealer confirmed vibration is present on 2022 model tested; stated it is normal design; mentioned Toyota RAV4 had similar issue with TSB issued; no TSB for Highlander
Power liftgate malfunction
Automatic liftgate fails to open or close reliably, particularly in cold weather. Vehicle owner drove unknowingly with liftgate open. Issue persists intermittently, sometimes working fine, often malfunctioning. Dealer denied warranty coverage citing dust/dirt on vehicle exterior as reason, despite owner purchasing extended warranty. Vehicle is subject to class action lawsuit alleging defective power-door components.
When: Present from purchase at 30,000 miles; ongoing
Symptoms owners cite: liftgate fails to close, especially in cold weather; manual push required to close liftgate; liftgate stops moving while opening or closing; intermittent operation—sometimes works, often malfunctions; owner drove vehicle unaware liftgate was partially open
Repairs/costs cited: Repair quote obtained but deemed very costly; owner declined work; issue noted immediately by dealership technician
Recalls/TSBs owners mention: Class action lawsuit ongoing for 2021+ Highlanders alleging defective power-door components; warranty denial based on exterior dirt
Rear A/C refrigerant leak—corroded lines
Rear air conditioning system failed due to refrigerant leak in A/C lines near exhaust area. Lines exhibit premature corrosion and cracking, likely from dissimilar metal corrosion or poor line placement near heat sources. Repair estimate exceeded $3,000 for all necessary rear A/C components. Dealer offered no warranty coverage or goodwill repair despite early mileage. Pattern of similar failures reported across 2019–2021 model years, some with recurring issues after repair.
When: Worsened after 10,000 miles; issue discovered after owner researched for over one year
Symptoms owners cite: rear A/C system failure; refrigerant leak in rear A/C lines; lines corroding or cracking near exhaust area; impaired windshield defogging and defrosting capability; potential for driver fatigue and reduced concentration in extreme temperatures
Repairs/costs cited: Dealership quoted over $3,000 to replace all necessary rear A/C components; no permanent fix found in some owner reports; repairs reported as recurring
Recalls/TSBs owners mention: No recall or TSB issued; some dealers stated Toyota is aware but no TSB exists; in some cases owners told no permanent fix exists; no warranty or goodwill repair offered
Front bumper clip failure and detachment
Lower and upper front bumper covers detach from vehicle while driving, often with minimal or no impact. Plastic retainer clips fail to hold bumper secure. NHTSA Recall 23V720000 addresses this; however, clip replacement remedy is not always available or possible if bumper damage has occurred. Detachment creates dangerous road hazard and potential secondary accidents. Some dealers initially refuse to perform recall work due to pre-existing damage or temporary repairs made by owner.
When: Occurs at various mileage points: 47,330 miles, 60,000 miles, after light impact; some at highway speeds 50-75 mph
Symptoms owners cite: lower bumper cover detaches while driving; upper bumper cover detaches or separates from lower cover; light impact to bumper causes detachment; bumper drags on ground; clips fail or come off plastic plugs securing bumper; no warning light illuminated before failure
Repairs/costs cited: Plastic plugs or retainer clips fail; some require full bumper replacement if clips cannot be replaced; temporary fixes (zip ties, duct tape, glue) used by owners; repair costs $200–$529.88 for diagnostic and parts/labor at some dealers
Recalls/TSBs owners mention: NHTSA Campaign 23V720000 issued; recall remedy not available for extended period; dealers acknowledge known issue but state no solution; some dealers refuse to perform work if vehicle has prior damage; dealer states Toyota corporate will not cover under recall if prior collision suspected
Sunroof spontaneous glass shattering
Panoramic sunroof glass spontaneously shatters without any external impact, often described as explosive in nature. Glass fails under normal driving conditions—highway speeds of 20–30 mph, calm weather, no debris impact. Shattering is violent enough to eject glass fragments from vehicle. Dealership service advisor noted glass appeared pushed outward as if pressure-induced from inside. Owners report this is a known recurring problem in 2020–2021 model year Highlanders.
When: At 10,000 miles; within 5 months of service
Symptoms owners cite: sunroof glass spontaneously shatters; loud explosive noise resembling gunshot; glass completely shattered with ~30% departing vehicle; remaining glass bowed outward; no external impact detected; glass shards etch roof paint and damage rear spoiler fairing
Repairs/costs cited: Dealership body shop repair estimate: $4,319; glass secured with tape and cardboard pending repair
Recalls/TSBs owners mention: No recall or TSB mentioned; issue reported as common in 2020–2021 Highlanders per owner research
Windshield premature cracking and failure
Windshields crack or fail repeatedly under normal driving conditions. Owner has had windshield replaced at least three times in approximately one year, with no high-speed highway travel or debris impact. No accidents reported. Pattern observed across multiple 2021–2023 model year Highlanders. Suggests underlying design defect in aerodynamics, structural support, or windshield material quality.
When: First crack noted at purchase inspection; subsequent cracks developed in spring 2025 and by February 2026; ~1+ year of ownership
Symptoms owners cite: windshield develops crack without apparent cause; repeated windshield failures—multiple replacements in short timeframe; cracks occur during normal, low-speed driving; no highway travel or debris impact reported; no accident history
Repairs/costs cited: Windshield replaced multiple times; repair performed at dealership prior to delivery and subsequently
Recalls/TSBs owners mention: No recall or TSB mentioned; issue discussed by numerous 2021–2023 Highlander owners online
Water intrusion from roof rack seals and A-pillar leaks
Failed roof rack seals and roof rail gaskets allow rainwater to enter vehicle through A-pillars and roof panel, contaminating door panels, headliner, and floor areas. Black mold and mildew develop inside vehicle panels, headliner, and potentially within air bag support arms. Water also leaks into headliner clips and support structure. Toyota issued Service Bulletin T-SB-0040-24 dated April 22, 2024 for 2020–2023 Highlanders; however, dealers refuse to perform repair under this bulletin. Risk of undetected damage to electrical wiring and air bag system functionality.
When: Water intrusion occurs during rain; mold discovered at ~5,000 to 10,000 miles; some detected only after owner complaint
Symptoms owners cite: water leaks from roof rack into A-pillars; water leaks into front driver's and passenger's side door panels; water leaks into headliner and roof area; black mold and mildew odor inside cabin; condensation seen in interior areas; windows fail to operate; headliner sagging; health symptoms reported: asthma and allergy issues in occupants
Repairs/costs cited: Headliner and headliner clips replacement needed; vehicle detailed to remove mold; interior repairs include water damage remediation
Recalls/TSBs owners mention: Toyota Service Bulletin T-SB-0040-24 issued April 22, 2024 for 2020–2023 model range; dealers refuse to perform repair under bulletin; Toyota refused to repair defect; manufacturer made aware but no assistance offered
Body panel cracking and door/window deformation
Both driver and passenger door panels develop growing cracks and structural defects, causing doors and windows to bow outward. Defect grows over years of ownership. Collision company estimates repair at $11,000+ and confirms manufacturing defect (no accidents or prior work on vehicle). Windows now exposed to elements due to bowing. Toyota refuses to acknowledge safety hazard or remedy defect beyond four-year warranty period, despite meticulously maintained service history and known hidden/growing nature of defect.
When: Manufacturing defects surfaced after several years of ownership; vehicle produced 10/2020 during COVID production period
Symptoms owners cite: growing cracks in passenger and driver-side door panels; doors bow outward; windows bow outward; windows exposed to elements; structural integrity compromise of door frames
Repairs/costs cited: Collision company estimate: $11,000+; confirmed no accidents or prior work caused defect
Recalls/TSBs owners mention: Toyota refused to acknowledge vehicle as safety hazard; refused to remedy defect citing 4-year age and mileage, despite known hidden/growing defect nature
Excessive wind noise from body seals
Excessive wind noise present since vehicle purchase, measured at 79 dB at 55 mph with windows up and radio off. Noise level confirmed identical on multiple 2021 Highlanders on dealer lot. Dealership acknowledged hearing excessive wind noise but declined repair because all vehicles exhibit same issue. Toyota service manager stated company acceptable noise limit is 100 dB, which exceeds CDC guidelines for hearing protection. Exposure to 79 dB over prolonged periods may damage hearing; 100 dB causes hearing loss after 15 minutes.
When: Present since new; brought to dealership attention at 5,000-mile and 10,000-mile services
Symptoms owners cite: excessive wind noise inside cabin; noise measured at 79 dB at 55 mph; noise present with windows up and radio off; noise identical on multiple 2021 Highlanders
Repairs/costs cited: No repair attempted; noise level documented with decibel meter
Recalls/TSBs owners mention: Dealership measured noise on two separate 2021 Highlanders, found same level, and deemed no defect; Toyota service manager stated acceptable noise limit is 100 dB
Engine undercarriage cover detachment
Plastic engine cover assembly (similar to recalled front lower bumper cover) detaches from undercarriage while driving on windy highway at 50–60 mph. No impact with obstructions reported. Cover drags and creates scraping noise. Dealership initial response suggests impact was required to cause detachment, but owner disputes this given vehicle clearance and driving conditions. Dealer quoted $200 diagnostic plus $529.88 for parts/labor but declined coverage.
When: Detached while pulling out of parking lot and during highway driving at 50–60 mph on windy day
Symptoms owners cite: scraping noise under vehicle; plastic engine cover assembly detaches; cover drags just in front of front tires; detachment occurs on windy day at 50–60 mph with no impact
Repairs/costs cited: Dealer quote: $200 diagnostic plus $529.88 parts and labor; similar to recalled front lower bumper cover assembly
Recalls/TSBs owners mention: Dealer stated repair not subject to recall; stated impact must have occurred to cause detachment (owner disputes)
Door lock failure and security vulnerability
Door locks fail to prevent unauthorized entry while vehicle is in park and driver is present and seated. Stranger was able to open driver and passenger doors despite vehicle being in park and doors appearing locked. Owner could not access SOS emergency button (cover would not open). Creates serious personal safety and security risk, particularly for single drivers or in emergencies not related to vehicle crash.
When: Occurred with vehicle at under 1,500 miles with vehicle in park
Symptoms owners cite: doors unlock or fail to stay locked while in park; driver-side door opened without key fob or unlock signal; back passenger door opened without key fob or unlock signal; doors appear locked but are accessible; SOS cover inoperable or difficult to access
Windshield trim detachment
Windshield side beveled trim on driver's side snaps and flies off vehicle while on highway, entering oncoming traffic. Passenger-side trim is also loose and nearly detaching. Creates hazard to other vehicles and occupants.
When: While driving on highway
Symptoms owners cite: driver-side windshield trim snaps and detaches; trim flies off into oncoming traffic; passenger-side trim loose and nearly detached
Recall parts availability delay—NHTSA 23V720000
NHTSA Recall 23V720000 (front bumper clips) issued but replacement parts unavailable for extended period. Multiple owners report Toyota has not provided remedy parts or timeline for availability. Delay prevents owners from completing recall repair, leaving vehicles with known safety defect unaddressed. One owner preparing for military PCS move unable to have recall completed due to parts unavailability.
When: Recall notification received 2023; parts still unavailable as of January 2025 (18+ months after recall issued)
Symptoms owners cite: recall notification received; parts not yet available for repair; extended delay in remedy availability; no timeline provided for parts availability
Recalls/TSBs owners mention: Toyota confirmed parts not yet available; VIN tool confirms parts distribution disconnect; dealers unable to complete recall work
Synthesized from 40 NHTSA owner complaints — unverified consumer allegations, summarized for patterns. The verbatim filings appear below.
What owners are reporting 1 most recent
While I was driving the vehicle on December 30, 2025 emerging on to the highway I heard a loud popping sound which I thought was one of the tires going flat when the plastic barrier underneath the car became unattached
Had body trouble with your 2021 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 2021 Toyota Highlander?
It's a meaningful issue. 40 complaints have been filed and the failure mode causes operational problems for owners. Repairs average $1,500.
At what mileage does the body typically fail?
Based on the 40 complaints filed, body issues most often appear around 30,333 miles. Some report problems earlier; some make it well past 150,000 with no symptoms. Maintenance habits matter — vehicles that received timely fluid services and were not regularly overworked tend to last longer.
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/2021/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.