The 2016 Toyota Highlander, a popular midsize SUV, has unfortunately been plagued by several significant issues that have led to multiple recalls. While Toyota has a reputation for reliability, even their vehicles can sometimes face problems.

In this article, we’ll examine three common issues affecting the 2016 Highlander model that have resulted in recalls issued by the National Highway Traffic Safety Administration (NHTSA). These problems range from brake system malfunctions to inaccurate load capacity labels and potential windshield defects. Understanding these issues is crucial for current owners and potential buyers alike, as they can impact both the safety and performance of the vehicle.

2016 Toyota Highlander Brake Fluid Problem

One of the most critical recalls for the 2016 Toyota Highlander involves a potential malfunction of the brake fluid level sensor. According to the NHTSA recall report, during the manufacturing process on a specific assembly line, some vehicles may have had their brake fluid level sensor wire harness improperly connected or left disconnected entirely.

The root cause of this issue stems from an error in the standardized work procedure on one production line, where the wire harness connection and inspection processes were mistakenly omitted. This oversight led to the possibility of the brake fluid level sensor wire harness not being properly connected, preventing the system from operating as intended.

The consequences of this malfunction are significant and potentially dangerous. If the wire harness is not properly connected, the vehicle’s system cannot detect when the brake fluid level drops below the specified threshold. Without this crucial warning, drivers may continue to operate their vehicles with dangerously low brake fluid levels, which could severely compromise braking performance and increase the risk of accidents.

To address this serious safety concern, Toyota has initiated a recall program. The company is notifying all known owners of the affected 2016 Highlander models, instructing them to bring their vehicles to an authorized Toyota dealership. At the dealership, technicians will verify the proper connection of the brake fluid level sensor wire harness. If the harness is found to be disconnected or improperly connected, they will rectify the issue by properly connecting it to the sensor.

It’s important to note that Toyota is offering this repair at no cost to vehicle owners, as it falls under the Toyota New Vehicle Limited Warranty. This recall underscores the importance of responding promptly to manufacturer recalls to ensure the continued safety and proper functioning of your vehicle.

2016 Toyota Highlander Label Problem

Another recall affecting the 2016 Toyota Highlander relates to an issue with the load-carrying capacity modification labels. This problem specifically involves vehicles that were accessorized by Southeast Toyota Distributors, LLC, a regional distributor for Toyota vehicles.

The root of this issue lies in the requirements set forth by the Federal Motor Vehicle Safety Standard (FMVSS) 110 S10. This standard mandates that when weight exceeding either 1.5 percent of the Gross Vehicle Weight Rating (GVWR) or 100 pounds is added to a vehicle between final certification and the first retail sale, a load-carrying capacity modification label must be added. Furthermore, the corrected values on this label must be accurate to within 1 percent of the actual added weight.

In the case of the affected 2016 Highlanders, Southeast Toyota Distributors did add the required labels when they installed accessories that exceeded the weight threshold. However, it was later discovered that some of these labels were not accurate within the required 1 percent margin of the actual added weight.

The inaccuracy of these labels poses a potential safety risk. If drivers rely on incorrect load capacity information, they may inadvertently overload their vehicles. An overloaded vehicle can experience reduced stability, increased stopping distance, and accelerated wear on critical components like brakes and tires, all of which increase the risk of accidents.

To remedy this situation, Southeast Toyota Distributors has initiated a recall process. They are notifying customers by mail about the noncompliance issue. As part of the recall, they will provide each affected owner with a new, accurate label. These labels are being custom-generated for each specific vehicle based on the net weight of the accessories actually installed.

Vehicle owners are instructed to install this new label over the existing inaccurate one. This simple but important step ensures that drivers have access to correct load capacity information, allowing them to use their vehicles safely within the designed weight limits.

2016 Toyota Highlander Windshield Problem

The third recall affecting some 2016 Toyota Highlanders involves a potential defect in aftermarket replacement windshields. These windshields, manufactured by Fujian Wanda Automobile Glass Industry between September 7, 2015, and March 10, 2018, have an attached wire harness that may be susceptible to water intrusion.

The problem originates from the design and installation of the wire harness. In these windshields, the harness is mounted between the laminates on the lower edge of the windshield and extends down into the engine compartment. The wire harness is composed of a polymer material that is sealed to the lower edge of the windshield with polyurethane glue. However, over time and when exposed to various environmental elements, this polymer material may allow water to penetrate the wire harness.

Once water enters the harness, it can migrate along the conductors inside and potentially come into contact with critical components of the vehicle, including the Engine Control Module (ECM) A43. If certain pins in the ECM A43 become significantly corroded or water-damaged, it can lead to serious operational issues.

The consequences of this water intrusion can be severe. Affected vehicles may experience difficulties starting, or in more serious cases, could stall during operation. Additionally, drivers might encounter situations where the vehicle has limited or no throttle response. These issues significantly increase the risk of accidents, especially if they occur unexpectedly during driving.

To address this safety concern, Fujian Wanda Automobile Glass Industry has initiated a voluntary safety recall. Their approach to remedying the situation is comprehensive:

1. They are working to contact all known end users of the affected windshields.
2. Affected owners will receive instructions on how to obtain a replacement windshield.
3. Wanda will direct users to a company-selected windshield installer who will replace the defective windshield.
4. As part of the replacement process, the installer will also inspect the ECM A43 and related components for any signs of corrosion or water damage.
5. If damage is detected in these components, Wanda will arrange for further inspection and necessary repairs at a Toyota dealership.

This recall highlights the importance of using high-quality, properly designed components in vehicle repairs and modifications. It also underscores the potential long-term consequences of seemingly minor design flaws in automotive parts.

2016 Toyota Highlander Owner Complaints

From NHTSA:

“I have had problems with the brakes since I bought the vehicle new in 2016. I have the brakes checked every year and when I had problems but they never found the problem why the brakes do not work. The worse accident was on November 19, 2022 when my wife was using the car. She was in the car alone. She went to brake and the brakes did not engage, she slammed on the brakes 4 times and the car did not even slow down and she rear-ended the car in front of her. The air bags did not engage and she was injured. The brakes do not always work, I have gone through stop signs and red lights but the dealership says there is no problem.”

From NHTSA:

“2 years ago I pulled my car, that was backed into the driveway out to turn it around to face in to the garage. As I pulled forward going very slowly I pressed on the brakes and the rubber pad on the pedal came off and caused my foot to come off of the pedal. I hit my wife’s car and caused some slight damage to my car and to hers. I contacted Toyota and they had my car inspected and gave me a report that the brakes worked fine. I have not replaced the rubber pad, because I am afraid the cover will come off again in a similar matter. I explained this to Toyota but they closed the case of my complaint. I believe this is a danger that can cause an accident.”

From a  CarComplaints.com:

“While driving on the road the engine shuts down….happened several times while my wife was driving and again when I was driving the car. Happened once while making a left turn in the middle of the intersection with kids in the back seat and was barely able to clear intersection due to momentum. Almost had a heart attack…with cars coming straight through honking…

When the engine shuts down the message on the screen says….engine has shut down put your vehicle in part and start again….and it does restart after I put it in park and start again

Talked to the dealership and getting them to look into it.”

Understanding Lemon Law and Your Rights

If you’re a 2016 Toyota Highlander owner who has experienced persistent issues with your vehicle, particularly related to the problems discussed in this article, it’s crucial to understand your rights under California’s Lemon Law. This law is designed to protect consumers who have purchased or leased vehicles with substantial defects that the manufacturer or dealer has been unable to repair after a reasonable number of attempts.

The California Lemon Law applies to both new and used vehicles that are still under the manufacturer’s original warranty. Under this law, if your Highlander has a substantial defect that impairs its use, value, or safety, and the manufacturer has been unable to repair the vehicle after a reasonable number of attempts, you may be entitled to significant remedies.

Key points to understand about the Lemon Law:

1. Reasonable Number of Repair Attempts: Generally, if the same problem has been subject to repair two or more times and still persists, it may qualify under the Lemon Law. For serious safety defects, even one repair attempt may be sufficient.
2. Days Out of Service: If your vehicle has been out of service for repairs for a cumulative total of 30 days or more (not necessarily consecutive), this could also qualify your vehicle as a “lemon.”
3. Warranty Period: The defect must have occurred within the vehicle’s warranty period, which is typically 3 years or 36,000 miles, whichever comes first.
4. Remedies: If your vehicle qualifies as a lemon, you may be entitled to a replacement vehicle or a refund of your purchase price, less a small mileage deduction for the use you’ve had of the vehicle.
5. Manufacturer’s Responsibility: If your claim is successful, the manufacturer is typically required to cover your legal fees and costs.

It’s important to note that while these recalls demonstrate known issues with the 2016 Highlander, your specific situation may vary. If you’ve experienced repeated issues with your vehicle, especially if they relate to safety or significantly impact the vehicle’s usability, it’s advisable to consult with a law firm experienced in Lemon Law cases.

Your Next Steps with a Problematic 2016 Toyota Highlander

Owning a vehicle with persistent problems can be frustrating, costly, and potentially dangerous. If you’re the owner of a 2016 Toyota Highlander and have experienced any of the issues mentioned in this article, or if you’ve had recurring problems that the dealer has been unable to fix despite multiple attempts, you may have a valid Lemon Law claim.

Don’t continue to struggle with a problematic vehicle. Reach out to Consumer Action Law Group today for a free consultation and case evaluation. Our team of experienced attorneys will review your situation, explain your rights under the California Lemon Law, and help you determine the best course of action.

Remember, under the Lemon Law, you may be entitled to a refund or replacement vehicle, and the manufacturer may be required to cover your legal fees. This means you can seek justice without worrying about the cost of legal representation.

Take the first step towards resolving your vehicle issues. Contact Consumer Action Law Group today and let us help you turn your lemon into lemonade. Your safety and satisfaction are our top priorities, and we’re here to fight for your rights as a consumer.