2004 Toyota Highlander Recalls, Problems & Maintenance

The 2004 Toyota Highlander has no open NHTSA recalls. Owners report 7 recurring issue clusters, led by “Steering intermediate shaft looseness and clunking.” Toyota's owner's manual splits service into Schedule 1 (severe) and Schedule 2 (normal). Most US drivers fall under Schedule 1 because it covers short trips, extreme temperatures, dusty roads, or heavy idling. The intervals below reflect Schedule 1 — the schedule Toyota recommends for typical real-world use.

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No open recalls on file. NHTSA lists no unrepaired safety recalls for this year, make and model. A recall can be issued at any time, and a specific car can still have one open — check yours by VIN at nhtsa.gov/recalls.

Known issues & problems for this vehicle

What drivers and federal regulators have officially reported about the 2004 Toyota Highlander.

Reported to NHTSA

Steering intermediate shaft looseness and clunking

STEERING

17 NHTSA complaints · 2006-12 → 2016-07

“HIGHLANDER RECENTLY RECEIVED 30K SERVICE AT TOYOTA DEALER. CAR MILEAGE WAS APPROXIMATELY 29K. THE SERVICE ADVISOR REPORTED THAT THE INTERMEDIATE SHAFT IN THE STEERING COLUMN WAS MAKING A CLUNK TYPE SOUND AND SHOULD BE REPLACED. HE BELIEVED HIGHLANDERS AND TACOMA'S HAD B”
— Owner report, NHTSA ODI #10219261
“NOISY STEERING SHAFT CAUSED ME TO TAKE CAR TO DEALERSHIP, WHERE I WAS TOLD THE SHAFT WAS 'WORN' (TINY BEARINGS WITHIN THE SHAFT WERE WORN) AND THE SHAFT WAS REPLACED. DEALER INFORMED ME THEY'D SEEN THIS PROBLEM ON OTHER TOYOTA HIGHLANDERS, AND ON THEIR ECONOMY TOYOTA PR”
— Owner report, NHTSA ODI #10185765
“2004 TOYOTA HIGHLANDER LIMITED STEERING SYSTEM LOOSENESS, CLUNKING. THE STEERING SYSTEM EXHIBITS EXCESSIVE FREEPLAY AND CLUNKING. A DEFECTIVE PART WAS REPLACED UNDER WARRANTY BUT NEEDS TO BE REPLACED AGAIN. THE VEHICLE HAS LESS THAN 30,000 MILES ON IT. *TR”
— Owner report, NHTSA ODI #10220323

Read all complaints on NHTSA →

Driver-side sun visor dropping from stowed position

VISIBILITY/WIPER

8 NHTSA complaints · 2010-04 → 2014-08

“THE DRIVER SUN VISOR KEEPS DROPPING FROM IT'S KEPT POSITION AND BLOCKS THE DRIVERS VIEW. THIS ALMOST CAUSED 2 ACCIDENTS WITH MYSELF AND THEN MY WIFE. THE SUDDEN DROPPING OF THE VISOR IS VERY DANGEROUS. I HAVE TALKED TO OTHER HIGHLANDER OWNERS AND THEY HAVE SIMILAR ISSUE”
— Owner report, NHTSA ODI #10554039
“SUN VISOR (DRIVER SIDE) FELL DOWN WHILE I WAS DRIVING ON THE FREEWAY WITH A SPEED OF ABOUT 65MPH.. IT BLOCKED MY VIEW. THANK GOD I WAS ABLE TO PULL OVER TO A SAFE PLACE. THE VISOR IS HOLDING IN PLACE BY A RUBBER BAND AND A STICK BUT THE PROBLEM IS THAT WHEN MY CAR IS PA”
— Owner report, NHTSA ODI #10478554
“DRIVER SUN VISOR DEFECT HAS CAUSED NUMEROUS SAFETY ISSUES AND NEAR ACCIDENTS. VISOR WILL NOT REMAIN UP WHILE DRIVING IN 2004 TOYATA HIGHLANDER. *TT”
— Owner report, NHTSA ODI #10407470

Read all complaints on NHTSA →

HVAC temperature control switching between hot and cold

EQUIPMENT

14 NHTSA complaints · 2009-01 → 2015-12

“TL*THE CONTACT OWNS A 2004 TOYOTA HIGHLANDER. THE CONTACT STATED THAT THE HEAT DOES NOT ALWAYS WORK IN THE VEHICLE. SHE MUST TOGGLE WITH THE KNOBS IN ORDER FOR THE HEAT TO FUNCTION PROPERLY. OFTENTIMES WHEN THE HEATING SYSTEM WAS ACTIVATED, IT WOULD BLOW COLD AIR. IN AD”
— Owner report, NHTSA ODI #10255968
“TL* THE CONTACT OWNS A 2004 TOYOTA HIGHLANDER. WHILE DRIVING APPROXIMATELY 45 MPH WITH THE AIR CONDITIONER ACTIVATED, HEAT BEGAN BLOWING FROM THE VENTILATION AS OPPOSED TO COLD AIR. THE FAILURE WOULD OCCUR INTERMITTENTLY. THE VEHICLE WAS NOT TAKEN TO THE DEALER FOR DIAG”
— Owner report, NHTSA ODI #10381108
“CONTROL PANEL OF 2004 TOYOTA HIGHLANDER. NUT SECURING THE TEMPERATURE CONTROL BUTTON IS LOOSE. CAUSES ENGINE AIR TO ENTER THE CABIN. A/C DOES NOT WORK; GETS JUST HOT ENGINE AIR. REFER TO SEVERAL OTHER COMPLAINTS AT: HTTP://WWW.TUNDRASOLUTIONS.COM/FORUMS/HIGHLANDER/10066”
— Owner report, NHTSA ODI #10331796

Read all complaints on NHTSA →

Stability control activation with unrequested braking

ELECTRONIC STABILITY CONTROL (ESC)

8 NHTSA complaints · 2007-11 → 2016-04

“I WAS DRIVING ABOUT 15 MPH ON A CITY STREETAND THE VSC INDICATOR LIGHT CAME ON AND THE VEHICLE STARTED BREAKING ON ITS OWN. A LOUD SCRAPPING SOUND WAS HEARD. IT WAS ABOUT 70DEGREES AND SUNNY AND THE CAR THOUGHT I WAS GOING DOWN A SLIPPERY SLOPE. I STOPPED THE VEHICLE. E”
— Owner report, NHTSA ODI #10854642
“TL*THE CONTACT OWNS A 2004 TOYOTA HIGHLANDER. WHILE DRIVING 5 MPH, THE CONTACT EXPERIENCED UNWANTED TRACTION CONTROL ACTIVITY, WHICH CAUSED THE VEHICLE TO BRAKE EXCESSIVELY. HE TOOK THE VEHICLE TO A LOCAL REPAIR SHOP AND THE MECHANIC REPROGRAMMED THE PCM MEMORY, WHICH R”
— Owner report, NHTSA ODI #10254022
“TL*THE CONTACT OWNS A 2004 TOYOTA HIGHLANDER. WHILE DRIVING 40 MPH, THE VEHICLE STABILITY SYSTEM ACTIVATED ON DRY SURFACE AND ATTEMPTED TO STEER THE VEHICLE. THE FAILURE AFFECTS THE STEERING AND OCCURS EVERY FEW FEET. SINCE THAT TIME, THE SYSTEM ATTEMPTS TO ACTIVATE AUT”
— Owner report, NHTSA ODI #10214029

Read all complaints on NHTSA →

Stripped cylinder head bolts with coolant loss

ENGINE AND ENGINE COOLING

13 NHTSA complaints · 2009-12 → 2026-05

“COOLANT LOSS DUE TO STRIPPED HEAD BOLTS IN THE ENGINE BLOCK. NO SMOKE OR HEAT OR WARNING ON DASH. HAVE TO CHANGE ENGINE BLOCK COSTING $6,000 FOR PARTS AND REPAIR. DEALER NOT RESPONDING. ALWAYS HAVE RECEIVED MAINTENANCE WITH THE SAME DEALER/SERVICE CENTER. *TR”
— Owner report, NHTSA ODI #10450090
“COOLANT LOSS DUE TO STRIPPED HEAD BOLTS IN THE ENGINE BLOCK. ENGINE OVER HEATED. NO HEAT.*TR”
— Owner report, NHTSA ODI #10383048
“TL* THE CONTACT OWNS A 2004 TOYOTA HIGHLANDER. THE CONTACT STATED THAT THE VEHICLE WAS LOOSING COOLANT BECAUSE OF A FRACTURED STRIP HEAD BOLT IN THE ENGINE, CAUSING THE VEHICLE TO SMOKE AND OVERHEAT. THE VEHICLE WAS TAKEN TO THE DEALER BUT WAS NOT REPAIRED. THE FAILURE”
— Owner report, NHTSA ODI #10370659

Read all complaints on NHTSA →

Melted headlamp and fog lamp lenses

EXTERIOR LIGHTING

10 NHTSA complaints · 2007-12 → 2014-07

“TL* THE CONTACT OWNS A 2004 TOYOTA HIGHLANDER. THE CONTACT STATED THAT THE HEADLIGHTS WOULD INTERMITTENTLY OVERHEAT AND MELT WITHOUT WARNING. THE DEALER ADVISED THE FAILURE WAS DUE TO THE BULB BECOMING EXTREMELY HOT AND MELTING THE HEAD LIGHT LENS. THE VEHICLE WAS NOT R”
— Owner report, NHTSA ODI #10332158
“RECENTLY DISCOVERED TWO WHITE MELTED BUMPS IN THE EXACT CENTER OF THE HEADLAMP CASING WHERE THE DAYTIME RUNNING LAMP BEAMS PASS THROUGH THE PLASTIC. HAVE ONLY HAD THE VEHICLE SINCE JULY 2010 AND THE INCIDENT OCCURED DURING A 19 HOUR DRIVE, MOST OF WHICH TOOK PLACE DURIN”
— Owner report, NHTSA ODI #10366129
“LATE LAST YEAR WE NOTICED THAT THE DAYRUNNING PORTION OF THE HEADLAMP COVER HAD MELTED ON THE INSIDE, NEXT TO THE TIP OF THE BULBS ON EACH SIDE. THERE IS NO WAY TO TURN THE DAYRUNNING FEATURE ON OR OFF, IT IS ALWAYS ON. NOT ONLY DOES THIS WEAR DOWN THE BATTERY, WHICH WE”
— Owner report, NHTSA ODI #10482596

Read all complaints on NHTSA →

Unintended acceleration at low speed

VEHICLE SPEED CONTROL

14 NHTSA complaints · 2010-02 → 2018-11

“TL* THE CONTACT OWNS A 2004 TOYOTA HIGHLANDER. THE CONTACT WAS PULLING OUT OF A PARKING SPACE AT SPEEDS OF 5 MPH WHEN THE VEHICLE ABNORMALLY ACCELERATED WITHOUT DRIVER INTENT. THE VEHICLE ACCELERATED TO APPROXIMATE SPEEDS OF 35 MPH. THE VEHICLE THEN STRUCK A TREE. THE C”
— Owner report, NHTSA ODI #10323747
“TL* THE CONTACT OWNS A 2004 TOYOTA HIGHLANDER. THE CONTACT STATED THAT WHILE PULLING INTO A PARKING SPACE, THE VEHICLE INDEPENDENTLY ACCELERATED. THE CONTACT WAS ABLE TO STOP THE VEHICLE BY APPLYING EXTREME FORCE TO THE BRAKES. THE FAILURE RECURRED ON A SEPARATE OCCASIO”
— Owner report, NHTSA ODI #10335791
“TL* THE CONTACT OWNS A 2004 TOYOTA HIGHLANDER. THE CONTACT STATED THAT WHILE ENTERING THE HIGHWAY, THE VEHICLE ACCELERATED WITHOUT MANUAL FORCE AND THE CONTACT CRASHED INTO A TREE. THE CONTACT SUSTAINED KNEE, CHEST AND ARM INJURIES. A POLICE REPORT WAS FILED AND THE VEH”
— Owner report, NHTSA ODI #10543458

Read all complaints on NHTSA →

Source: NHTSA Office of Defects Investigation (ODI). Complaint data refreshed Sep 20, 2026. Investigation data refreshed Sep 20, 2026.

We display NHTSA's record with attribution; we don't editorialize on what these complaints mean for any specific vehicle.

Raw data + downloads for this vehicle →

Essential maintenance

Critical for safety and preventing major damage

Engine Oil & Filter

Every 5,000 mi

Replace 0W-20 full-synthetic oil and filter every 5,000 miles under Schedule 1, or 10,000 miles under Schedule 2. Toyota covers the first 2 oil changes through ToyotaCare.

Estimated cost — typical U.S. ranges

Dealer

~$120–$160

Shop

~$85–$115

DIY

~$25–$55

Full synthetic costs more than conventional. 5-quart 0W-20 + filter is the typical bill.

Tire Rotation

Every 5,000 mi

Rotate tires every 5,000 miles. Toyota recommends rotation at every oil change to maximize tire life on FWD and AWD models.

Estimated cost — typical U.S. ranges

Dealer

~$85

Shop

~$60

DIY

Free

Often free at the shop where you bought the tires — worth asking before paying.

Brake Inspection

Every 5,000 mi

Inspect brake pads, rotors, and parking brake every 5,000 miles. Toyota recommends measuring pad thickness at each service.

Estimated cost — typical U.S. ranges

Dealer

~$85

Shop

~$60

DIY

Free

Most shops do this free as a courtesy with any service. Don't pay separately if you can avoid it.

Brake Fluid

Every 30,000 mi

Replace DOT 3 brake fluid every 30,000 miles or 36 months. Critical for the integrity of the ABS, VSC, and brake assist systems.

Estimated cost — typical U.S. ranges

Dealer

~$180–$200

Shop

~$125–$140

DIY

~$10–$25

DOT 3 or 4 — match the cap. Vacuum bleeders make this a one-person DIY.

Important maintenance

Keeps your vehicle running smoothly and efficiently

Engine Air Filter

Every 30,000 mi

Replace the engine air filter every 30,000 miles. Earlier under Schedule 1 if driven on unpaved roads.

Estimated cost — typical U.S. ranges

Dealer

~$60–$95

Shop

~$45–$70

DIY

~$15–$40

5-minute job on most cars; the airbox lid usually has clips, no tools needed.

Automatic Transmission Fluid

Every 60,000 mi

Toyota labels ATF as 'lifetime fill' on most automatics, but recommends inspection and replacement every 60,000 miles under severe service. Use Toyota WS or Type-IV — no substitutes.

Estimated cost — typical U.S. ranges

Dealer

~$330–$500

Shop

~$235–$355

DIY

~$60–$180

Some sealed transmissions have no dipstick — fill is precise and best left to a shop. Many drivers can still DIY drain-and-fill.

Spark Plugs

Every 120,000 mi

Toyota iridium-tipped spark plugs are rated for 120,000 miles. Earlier replacement reduces fuel economy and can cause misfires on direct-injection engines.

Estimated cost — typical U.S. ranges

Dealer

~$285–$390

Shop

~$200–$275

DIY

~$25–$100

Iridium plugs cost more but last 100k+ miles. V6/V8 access varies wildly — some are tough.

Super Long Life Coolant (SLLC)

Every 50,000 mi

Toyota SLLC (pink): first change at 100,000 miles, then every 50,000 miles. Do not substitute green or orange coolant — it will damage the cooling system seals.

Estimated cost — typical U.S. ranges

Dealer

~$285–$330

Shop

~$200–$235

DIY

~$25–$60

Use the manufacturer-specified coolant — wrong color/chemistry can damage the cooling system.

Recommended maintenance

Extends the life of your vehicle and improves comfort

Cabin Air Filter

Every 30,000 mi

Replace the cabin air filter every 30,000 miles, sooner in dusty climates. Located behind the glove box on most Toyota and Lexus models.

Estimated cost — typical U.S. ranges

Dealer

~$60–$95

Shop

~$45–$70

DIY

~$15–$40

Usually behind the glovebox. Shops charge labor for a 10-minute job — easy DIY win.

Serpentine / Drive Belt Inspection

Every 60,000 mi

Inspect the serpentine belt and tensioner every 60,000 miles. Toyota uses long-life EPDM belts that rarely fail before 100,000 miles.

Estimated cost — typical U.S. ranges

Dealer

~$195–$235

Shop

~$135–$165

DIY

~$20–$50

DIY-friendly if you can reach the tensioner. Inspect for cracks rather than swap on a strict mileage interval.

Timing Chain — No Replacement

On condition / lifetime

Toyota's 2AR-FE, 2GR-FKS, A25A-FKS, and most Toyota engines built since 2010 use a timing chain rated for the life of the engine. No scheduled replacement.

Estimated cost — typical U.S. ranges

Dealer

~$85

Shop

~$60

DIY

Pro only

Timing chains are normally lifetime. Listen for rattle on cold start — that's the actionable signal. Replacement is major work, quote separately.

Fatal crash history & reported problems

Occupant deaths in fatal crashes (FARS)

95 crashes 1990–2024

How the 95 occupant deaths break down

71

driver deaths

22

passenger deaths

2

not recorded by seat

95

occupant deaths

Crash years covered: 1990–2024 This model year first appears in 2004 crashes. Older models have had more years on the road to appear in these crashes, so a higher count here does not by itself mean a vehicle is less safe.

FARS counts every occupant death in a fatal crash, whatever the cause — it does not mean the vehicle was at fault or defective. Counts are not adjusted for how many of each vehicle are on the road. How to read this number

FARS 2024 data is an annual report file. NHTSA revises these records when the final file is published, so this count can change.

Why we show driver deaths too

Every vehicle has exactly one driver seat, so driver deaths line up fairly when you compare one model to another. Occupant deaths include passengers, so a three row SUV can show a higher number than a two seat car simply because it carries more people.

Both figures are plain counts, not rates. A rate would need to know how many of each vehicle are on the road, and that registration data is not public, so we do not publish rates or scores of any kind.

IIHS publishes driver death rates using this same driver only idea, paired with a registered vehicle years denominator we do not have. Their rates and these counts answer different questions, so do not read either number here as a safety rating.

Owner-reported problem signals

Separate from the federal fatality data above: complaints owners filed with NHTSA about this year and model. These are reports of problems, unverified, and are counted here only as signals.

32

complaints mentioning a crash

3

complaints mentioning a fire

Reviewed known issues for this vehicle

Typical U.S. ranges. Actual quotes vary by shop, parts choice, and vehicle condition.

How we estimate: Dealer = OEM parts × 1.4 + labor × $165/hr. Shop = parts + labor × $115/hr. DIY = parts only.

This maintenance schedule for the 2004 Toyota Highlander reflects Toyota's published service intervals and the Maintenance Required Light system. Your actual service needs may vary based on driving conditions, climate, and vehicle usage. Always consult your owner's manual for model-specific recommendations.