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Airbag / Occupant Detection Defect - Airbag May Not Deploy Correctly
airbag warning light; passenger airbag may not deploy; SRS warning; occupant detection fault
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4 NHTSA recalls, front axle TSB, and transmission issues plague the 2024 Toyota Grand Highlander. California owners: learn your rights under Song-Beverly.
You paid $46,000 to $62,000 for Toyota's boldest three-row SUV in years, a nameplate built to outrun the Highlander while carrying the reliability crown Toyota has spent decades earning. The 2024 Grand Highlander promised more room, more power, and the dependability of a company that wrote the book on quality. Instead, many first-model-year buyers have spent their early ownership months making dealership appointments rather than enjoying the road. Toyota issued a stop-sale curtain airbag recall (24V461) within months of launch, covering roughly 111,700 vehicles because the side curtain bags could deploy outside an open window in a crash rather than protecting occupants. A federal labeling recall followed. Then in late 2025 and early 2026, two more recalls emerged: one for instrument panel software that could blank out speed, brake-system warnings, and tire pressure displays at startup (25V595), and another for the rearview camera that can freeze in reverse (25V744). Beyond formal recalls, the NHTSA complaint database documents owners returning for clicking front axles covered by TSB T-SB-0082-24, transmission hesitation addressed by TSB T-SB-0017-24, engine check lights from a VVT software error (Service Campaign 24TC05), and a fuel tank that shuts off at 12 gallons on a 17-gallon fill. Consumer Reports flags the drive system as the 2024 Grand Highlander's leading reliability weakness. TSS 3.0 phantom braking at highway speeds has been logged in NHTSA complaints as a rear-collision hazard. None of this makes the Grand Highlander a bad vehicle outright, but it makes this first-model-year launch the clearest evidence that even Toyota carries a different risk profile on debut platforms. If your Grand Highlander has been back to the dealer for the same symptom more than once, California law may give you options your service advisor has not mentioned.
The issues owners report most, ranked by severity — each one verified against a cited NHTSA source.
airbag warning light; passenger airbag may not deploy; SRS warning; occupant detection fault
warning light; recall notice; repeated dealer repair
brake pedal problem; reduced braking; unexpected braking; brake warning light
backup camera blank; screen goes black in reverse; rearview camera distorted
clicking or popping noise from front axle when turning and accelerating; clunking when making turns at low speed; rotational noise from one or both front wheels during cornering; noise worsens in cold weather; axle noise present without grease leak
hesitation when accelerating from a stop; car bucks or jerks between first and second gear; delayed power delivery with steady throttle 0-40 mph; transmission feels like it slips before engaging; car hops several times when accelerating at low speed; multiple transmission failure codes in TCM; vehicle feels unsafe in traffic during hesitation event
A settled Margarian Law case on this exact model, published with the actual settlement math.
Open any defect for the symptoms and why it matters for a California lemon-law claim. Each is tied to a cited NHTSA source.
airbag warning light; passenger airbag may not deploy; SRS warning; occupant detection fault
Recall 24V461 directly concerns airbag non-deployment during side-impact crashes when windows are open — a clear safety defect with life-safety consequences. Under Song-Beverly, if a dealer fails to complete the airbag assembly replacement within a reasonable time after the owner presents the vehicle, or if the replacement parts are unavailable for an extended period (which occurred during the Oct 2024 rollout), time out of service accrues toward California's 30-day / 18-month statutory threshold. Owners who received a stop-sale letter but could not get repairs scheduled promptly should document all communication with the dealer and Toyota.
Dealers will replace the driver and passenger curtain shield air bag assemblies, free of charge. Owner letters were mailed November 4, 2024. Owners may contact Toyota customer service at 1-800-331-4331. Toyota's numbers for this recall are 24TB09/24TA09 and Lexus' numbers are 24LB05/24LA05.
warning light; recall notice; repeated dealer repair
Recall 24V548 corrects an inaccurate load-capacity label on GST-accessorized vehicles; the defect is a federal labeling noncompliance, not a mechanical failure. As a standalone issue this is unlikely to support a Song-Beverly claim because it does not substantially impair vehicle use, value, or safety as typically construed. However, if this recall repair is combined with other open recall or warranty work requiring multiple dealer visits, total repair days count toward the 30-day out-of-service threshold under Song-Beverly.
GST will mail new labels to owners, free of charge. Owner notification letters were mailed September 16, 2024. Owners may contact GST customer service at 1-800-444-1074. GST's number for this recall is 24R2.
brake pedal problem; reduced braking; unexpected braking; brake warning light
Recall 25V595 involves an instrument panel software defect that can blank out vehicle speed, brake-system warning lights, and tire-pressure indicators at startup — exactly the information a driver needs to detect a brake failure in real time. NHTSA classified this as a safety recall. Under Song-Beverly, a safety-related defect requiring a dealer OTA or in-person software update that does not fully resolve (instrument panel still goes blank after update) is a qualifying repeat-repair scenario. Owners should request printed work orders for every visit, even OTA-update visits, to establish the repair-attempt record.
Dealers will update the instrument panel software over-the-air (OTA) for non-PHEV vehicles, free of charge. For PHEV vehicles, dealers will inspect the instrument panel assembly, and either replace it, or update the software, free of charge. Owner letters were mailed December 5, 2025. Additional let
backup camera blank; screen goes black in reverse; rearview camera distorted
Recall 25V744 addresses a rearview camera that freezes or goes blank during reverse — a federal FMVSS 111 (Rear Visibility) noncompliance. A blank backup camera at low speed in a parking lot is a safety hazard, particularly for pedestrians and cyclists. If the parking-assist software update does not permanently resolve the freezing (some owners report recurrence), each return dealer visit for the same blank-camera symptom counts as a distinct repair attempt under Song-Beverly. Two or more failed repair attempts for a safety system that fails to meet federal safety standards is a strong predictor of lemon-law eligibility in California.
Dealers will update the parking assist software, free of charge. Owner letters were mailed January 2, 2026. Owners may contact Toyota's customer service at 1-800-331-4331. Toyota's numbers for this recall are 25TB13 and 25LB06. Subaru's number for this recall is WRE25.
clicking or popping noise from front axle when turning and accelerating; clunking when making turns at low speed; rotational noise from one or both front wheels during cornering; noise worsens in cold weather; axle noise present without grease leak
Toyota acknowledged this defect via a factory TSB and authorized drive shaft replacement at no cost. Under Song-Beverly, if the dealer fails to remedy the clicking after a reasonable number of attempts (two or more for a safety-related symptom, or four-plus for non-safety), the owner may be entitled to a buyback or replacement. The widespread complaint volume and early-production onset strongly supports a 'known defect' argument even before formal recall.
Replace one or both front drive shaft assemblies with updated part per T-SB-0082-24. Covered under Toyota powertrain warranty (5 yr / 60,000 mi). Superseded by T-SB-0028-26 (April 2026) for vehicles still exhibiting the condition.
hesitation when accelerating from a stop; car bucks or jerks between first and second gear; delayed power delivery with steady throttle 0-40 mph; transmission feels like it slips before engaging; car hops several times when accelerating at low speed; multiple transmission failure codes in TCM; vehicle feels unsafe in traffic during hesitation event
Toyota issued a TSB confirming the transmission hesitation is a known defect requiring ECM recalibration. Owner reports of recurrence after the software update are critical under Song-Beverly — each return to the dealer for the same complaint counts as a repair attempt. Three or more failed software attempts for a drivability defect that impairs vehicle use may support a lemon-law buyback claim.
ECM software recalibration update per T-SB-0017-24 (Hybrid) and any applicable TCM update for ICE-Gas trims. No hardware replacement prescribed. Dealer must use latest Toyota Techstream calibration file; verify ECM version after flash.
check engine light on after cold start; MIL illuminates in cold weather; DTC P05CE00 stored in ECM; engine warning light comes on and off; rough idle briefly at cold start; car hesitates then warning light appears
Toyota proactively issued a special service campaign (24TC05) acknowledging the ECM programming defect before many owners even reported it, establishing manufacturer notice. If the MIL returns after the ECM flash — as can occur if the calibration update does not fully resolve the VVT timing issue — subsequent dealer visits for the same DTC count as additional repair attempts toward Song-Beverly eligibility.
ECM flash reprogramming with updated calibration under Special Service Campaign 24TC05. ECM hardware replacement is explicitly contraindicated by Toyota. Dealer clears DTC and performs cold-soak test drive to confirm resolution.
gas pump shuts off early; fuel gauge reads full after only 12-13 gallons; cannot add more than 12 gallons from empty; fuel tank feels full but range shows low; fuel door problem; fuel pump cuts off at pump; gas tank won't fill to capacity
Toyota was aware of this fuel system defect before the vehicle launched (TSB issued November 2023). Owners who make multiple dealership visits for the same underfill complaint and receive only partial fixes — or are told the vehicle 'meets spec' despite NHTSA investigator involvement — may have a documented repair-attempt record supporting a Song-Beverly claim. The defect materially impairs vehicle use by reducing effective driving range.
Authorized repair includes replacement of fuel pump assembly, fuel tank, and associated vapor hoses, plus software reflash of fuel gauge calibration. Initial software-only fix may provide partial improvement (15 gal fillable) but full hardware replacement may be required for complete resolution.
car slams on brakes with nothing in front; emergency braking activates on highway for no reason; pre-collision warning goes off without obstacle; automatic braking engages on overpass shadows or bridge expansion joints; following cars nearly rear-end me after unexpected braking; pre-collision system malfunction warning; adaptive cruise control disengages unexpectedly on long highway drives
Phantom braking on a highway is a safety defect — it creates rear-collision risk for following traffic and can cause the owner to lose control. NHTSA complaint ODI 11728923 documents a forward collision avoidance system failure. If a dealer performs TSS recalibration but the false activations continue, each return visit counts as a repair attempt under Song-Beverly. Multiple failed recalibrations for a safety system defect is one of the stronger fact patterns for California lemon-law eligibility.
Dealer performs TSS 3.0 forward camera and radar recalibration. Apply latest TSS software update via Toyota Techstream. Clean radar sensor cover (behind Toyota emblem) and windshield camera area. If symptoms persist after calibration, replace front radar sensor assembly.
sunroof glass explodes or shatters without impact; loud bang from roof while driving; glass rains down on rear seat passengers; moonroof rattle and buzzing at highway speeds; sunroof makes noise over rough roads; headliner vibrating near moonroof; sunroof creak when opening or closing
If a panoramic moonroof spontaneously shatters — particularly over rear-seat occupants — this is a safety defect regardless of Toyota's warranty-denial stance. California's Song-Beverly Act covers defects that impair the use, value, or safety of the vehicle. Owners who receive repeated warranty denials for shattering (citing 'external damage') despite the fracture pattern indicating spontaneous failure have a viable lemon-law angle, particularly if they can document the shatter pattern was not caused by external impact.
For shattering: moonroof assembly replacement required; Toyota may deny warranty coverage citing 'external impact' — owners should photograph glass shatter pattern (spontaneous shattering shows outward fracture, not impact point). For rattle: dealer adds adhesive-backed felt pads between headliner and moonroof frame and re-secures wire harness clips.
steering recall notice; loss of steering control; abnormal steering feel, noise, or pull after a pothole or curb impact; repeated dealer repair
Recall 26V598000 documents a manufacturing error in the front steering knuckles of certain 2026 vehicles that can cause the knuckle to crack and break, resulting in a loss of steering control. Toyota's remedy is inspection and replacement of the front steering knuckles, but owner letters are not expected until November 2, 2026. A steering component that can fracture is a safety-critical defect under Song-Beverly. A California owner who reported steering noise, abnormal steering feel, or a knuckle concern before the remedy is available, or whose dealer cannot complete the inspection and replacement within a reasonable time, should keep every repair order; each unsuccessful visit for the same steering condition counts toward the repair-attempt threshold, and cumulative days out of service also matter.
Dealers will inspect and replace the front steering knuckles, as necessary, free of charge. Owner notification letters are expected to be mailed November 2, 2026. Owners may contact Toyota's customer service at 1-800-331-4331. Toyota's numbers for this recall are 26TA19 and 26LA09.
open
Toyota Motor Engineering & Manufacturing (Toyota) is recalling certain 2026 Lexus TX350, RX350 Hybrid, RX350, RX500 Hybrid, TX500 Hybrid, Toyota Grand Highlander, and Grand Highlander Hybrid vehicles. Due to a manufacturing error, the front steering knuckles may crack and break, which can result in a loss of vehicle steering control.
remedy available
Toyota Motor Engineering & Manufacturing (Toyota) is recalling certain 2022-2026 Toyota, Lexus, and Subaru Solterra vehicles equipped with a Panoramic View Monitor (PVM) system. Please see the recall report for a complete list of models. A software error may cause the rearview camera to freeze or display a blank screen when the vehicle is in reverse. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard (FMVSS) number 111, "Rear Visibility."
remedy available
Toyota Motor Engineering & Manufacturing (Toyota) is recalling certain 2023-2024 Toyota Venza, 2023-2025 RAV4 Prime, RAV4, Highlander, GR Corolla, Crown, 2024-2025 Lexus TX, LS, Toyota Tacoma, Grand Highlander, and 2025 Lexus RX, Toyota Crown Signia, Camry, RAV 4 Plug-in Hybrid (PHEV), and 4 Runner vehicles. Due to an error in the instrument panel software at vehicle startup, the instrument panel may fail to display vehicle speed, brake system, and tire pressure warning lights.
remedy available
Gulf States Toyota, Inc. (GST) is recalling certain Toyota 2023 GR Supra, 2024 4 Runner, Corolla, Grand Highlander, Grand Highlander Hybrid, Land Cruiser Hybrid, Tacoma, Tacoma Hybrid, 2023-2024 BZ4X, Corolla Cross Hybrid, GR Corolla, GR86, Highlander, Highlander Hybrid, Prius, Prius Prime, Sequoia Hybrid, Tundra, Tundra Hybrid, Venza Hybrid, 2023-2025 Crown, and 2025 Camry Hybrid vehicles equipped with GST accessories. The load carrying capacity modification label may display inaccurate added weight values. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard number 110, "Tire Selection and Rims."
remedy available
Toyota Motor Engineering & Manufacturing (Toyota) is recalling certain 2024 Toyota Grand Highlander, Grand Highlander Hybrid, Lexus TX350, TX500 Hybrid, and TX550 Hybrid+ vehicles. The driver and passenger side curtain air bags may not unroll as intended and could partially deploy outside of an open window. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard number 226, "Ejection Mitigation."
Every item below comes from this vehicle's documented defects. The more you recognize, the more a free case review is worth your time.
California's Song-Beverly Consumer Warranty Act applies to new vehicles sold or leased in California under a manufacturer's warranty. If a covered defect substantially impairs the use, value, or safety of your vehicle and Toyota has been given a reasonable number of attempts to repair it, you may be entitled to a full refund or a comparable replacement. Toyota must also pay your attorney's fees if you prevail — meaning many Song-Beverly claims cost the owner nothing in legal fees. For the 2024 Grand Highlander, the most qualifying defect patterns are: (a) Curtain airbag recall 24V461 — two failed safety-defect repair attempts may be enough; (b) Instrument panel software recall 25V595 — a blank safety display is a safety defect; (c) Front driveshaft clicking under TSB T-SB-0082-24 — each return after axle replacement counts; (d) Transmission hesitation under TSB T-SB-0017-24 — multiple ECM reflashes for the same symptom build a strong record; (e) TSS 3.0 phantom braking — false emergency stops create rear-collision risk and are a safety defect. A separate path exists if the vehicle is out of service 30 or more cumulative days within 18 months or 18,000 miles. Days waiting for recall parts count. Keep every repair order and loaner receipt. This is general information, not legal advice. No attorney-client relationship is formed. Laws change; consult a California lemon-law attorney for your specific facts. Law as of Jun 29, 2026.
“Could not duplicate” doesn't mean the defect isn't real. Here's exactly what to do to protect a potential California lemon-law claim.
Document the moment it happens. Photos, video, and screenshots of any warning lights — with the date and the mileage.
Get a repair order every visit — even “found nothing.” That paperwork is the foundation of a claim.
Check your VIN at nhtsa.gov/recalls. Note any recall that has no available remedy yet.
Track your out-of-service days. California law counts the cumulative days your vehicle spends in the shop.
Keep loaner & rental records. Alternate-transport paperwork during long repairs matters.
Save everything in one place. Symptoms, dates, repair orders, and every repeat visit — the intermittent ones especially.
1. Write it down immediately. Note the exact date, time, weather, speed, road type, and what the car was doing. Grand Highlander issues like TSS phantom braking and transmission hesitation are intermittent — the dealer cannot reproduce what you cannot describe. 'Car hesitates around 15 mph on an uphill' is actionable. 'Car acts weird' is not. 2. Record video every time it recurs. Mount a phone facing the dashboard and road if possible. The camera freeze from recall 25V744 and the instrument panel blank from recall 25V595 last only seconds — video is often the only proof. Upload to cloud immediately for date-stamped evidence. 3. Pull DTCs before driving to the dealer. A $25 OBD-II Bluetooth reader captures DTC P05CE00, TCM fault codes, or ADAS codes before the dealer clears them. Save the scan report as a PDF. 4. Insist the repair order describes your symptom — not the dealer's conclusion. Before handing over keys, ask the service writer to write: 'customer reports clicking from front left axle when turning left while accelerating, present since 300 miles.' That language is what counts as a repair attempt under Song-Beverly. 'Inspected — no concern found' does not close the attempt if your symptom was never actually duplicated. 5. Check all four open recalls every visit. Ask the dealer to run a VIN recall check and confirm which of 24V461, 24V548, 25V595, and 25V744 are complete. Days waiting for recall parts count toward Song-Beverly's 30-day out-of-service threshold. Request written confirmation of parts-availability timelines. 6. Escalate to Toyota at 1-800-331-4331. After two failed repair attempts for the same defect, open a corporate case. Request a case number in writing. Documented corporate refusal to remedy is strong evidence in a Song-Beverly proceeding.
The 2024 Toyota Grand Highlander is a well-designed three-row SUV — but its debut has produced a defect profile unusual for Toyota. Four NHTSA recalls in two years (two safety-coded), a manufacturer-acknowledged front axle TSB, a transmission hesitation TSB, a pre-launch fuel-fill TSB, and an engine VVT campaign collectively signal that TNGA-K platform quality controls struggled with this nameplate launch. Most owners will complete their recalls without drama. But owners cycling through repeat dealer visits for the same symptom should know California law was written exactly for this fact pattern. Document everything, keep every repair order, and ask about your rights before the warranty clock runs out.
— The Margarian Law team
If your 2024 Grand Highlander has been to the dealer two or more times for clicking axles, transmission hesitation, a blank instrument panel, phantom braking, or any airbag-related issue, California's lemon law may entitle you to a buyback or replacement. Margarian Law offers a free case review — save your repair orders and call us before your warranty window closes.
The clicking or popping sound from the front of your 2024 Grand Highlander when turning and accelerating is a known defect addressed by Toyota Technical Service Bulletin T-SB-0082-24. The bulletin covers both Grand Highlander and Grand Highlander Hybrid vehicles produced before a specific VIN cutoff. The root cause is early-production front drive shaft assemblies with inadequate CV joint grease distribution — the condition can occur even without a visible grease leak. Toyota authorized replacement of the affected drive shaft assembly at no cost under the standard 5-year / 60,000-mile powertrain warranty. Ask your dealer to check TSB T-SB-0082-24 against your VIN. If the clicking returns after the first replacement, document every visit: repeated failures for the same TSB-acknowledged defect can support a California lemon-law claim. []
NHTSA Safety Recall 24V461 (Toyota reference 24TA09) covers approximately 111,700 model-year 2024 Grand Highlander and Grand Highlander Hybrid vehicles. The defect: driver and passenger side curtain shield airbags may not unroll correctly during a crash if a window is open, reducing occupant protection and creating a federal FMVSS 226 noncompliance. Toyota issued a stop-sale and began mailing owner letters November 4, 2024. The remedy is dealer replacement of both curtain airbag assemblies at no charge. If your dealer says replacement parts are not yet available, Toyota is required by NHTSA regulations to provide a timeline estimate. Request that in writing. Every day your vehicle is at the dealer awaiting parts counts as a day out of service — California's Song-Beverly Act allows a lemon-law claim if your vehicle is out of service for 30 or more cumulative days within 18 months of purchase. Contact Toyota at 1-800-331-4331 to open a case and get a parts-availability commitment in writing. []
Acceleration hesitation and jerking on the 2024 Toyota Grand Highlander Hybrid at 0–40 mph is a documented defect covered by Toyota TSB T-SB-0017-24. The bulletin confirms the Engine Control Module (ECM) logic was not properly calibrated for the hybrid powertrain's torque-blending at low speeds, causing the 8-speed system to hesitate before engaging. The fix is an ECM software recalibration at the dealer — no hardware replacement is needed. However, some owners report the hesitation returns after the initial software flash. If you bring the vehicle back in for the same symptom after the first update, that is a second repair attempt under California's Song-Beverly Act. ICE-Gas Grand Highlander owners (non-hybrid) who experience similar hesitation and jerking should ask the dealer to check for any applicable TCM or ECM calibration updates, as NHTSA complaint records also document powertrain issues on non-hybrid trims. Keep every repair order — the repair-attempt count is what drives lemon-law eligibility. []
If the 12.3-inch instrument panel on your 2024 Toyota Grand Highlander goes blank or fails to display vehicle speed, brake warnings, or tire pressure indicators when you start the car, NHTSA Safety Recall 25V595 (Toyota reference 25TA08) most likely applies to your vehicle. A software error causes the combination meter's memory device to degrade faster than normal, resulting in a blank display at startup. Toyota mailed owner notification letters December 5, 2025. The remedy for non-PHEV vehicles is an over-the-air (OTA) or dealer software update, free of charge. For PHEV models, dealers will inspect the instrument panel assembly and either update the software or replace the unit. If your dealer has already performed the software update but the blank-screen condition recurs, return to the dealer and document the visit — each return visit for the same symptom is a repair attempt. A blank instrument panel that hides brake-system warnings is a federal safety standard violation and a strong basis for a Song-Beverly claim if repairs are not permanently resolved. Contact Toyota at 1-800-331-4331. []
Unexpected automatic braking on the 2024 Toyota Grand Highlander — sometimes called 'phantom braking' — is triggered by the Toyota Safety Sense 3.0 (TSS 3.0) pre-collision system misidentifying stationary objects such as overpass structures, road signs, and bridge expansion joints as collision threats. The system applies full emergency braking with no obstacle present, creating an immediate rear-collision risk from following traffic. NHTSA complaint ODI 11728923 documents a forward collision avoidance system failure on a 2024 Grand Highlander. The dealer remedy is TSS 3.0 forward radar recalibration and software update; if false activations continue, the front radar sensor assembly may need replacement. Dynamic radar cruise control (DRCC) dropout — where the adaptive cruise disengages mid-highway with an 'ACC Unavailable' message — is a related symptom. Because phantom emergency braking is a safety hazard, two or more dealer visits for this issue without a permanent fix may support a California lemon-law claim. Adjust PCS sensitivity in settings as a short-term measure while awaiting the fix, but do not turn the system off entirely as a long-term solution. []
Whether any specific 2024 Grand Highlander qualifies as a lemon under California's Song-Beverly Consumer Warranty Act depends on your individual repair history — not a general statement about the model. However, the 2024 Grand Highlander's documented defect record creates several viable fact patterns: (1) Two or more failed attempts to repair a safety defect (airbag, instrument panel blank, phantom braking, or rearview camera failure) may be enough; (2) Four or more failed attempts for a non-safety drivability defect (front axle clicking, transmission hesitation, fuel underfill, engine MIL); or (3) Thirty or more cumulative days out of service within 18 months of purchase, including recall-parts waiting time. Gather all your repair orders — the date, mileage, and written complaint description on each RO is the evidence that drives the case. The 2024 Grand Highlander's four NHTSA recalls, two factory TSBs for drivetrain defects, an engine VVT campaign, and a fuel-fill TSB issued pre-launch give a California attorney meaningful leverage even before the first repair attempt. Margarian Law offers a free case review with no obligation. []
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