NHTSA Investigates 87,000 Grand Highlander SUVs Over Grille Design

NHTSA Opens Investigation Into Grand Highlander Grille Design

On August 20, the U.S. National Highway Traffic Safety Administration (NHTSA) announced an investigation covering 87,000 2024-2026 Grand Highlander and Grand Highlander Hybrid SUVs. The Grand Highlander grille investigation focuses on a front-end design featuring large open apertures without a protective screen positioned behind the grille. According to NHTSA, this configuration may allow rocks and other road debris to reach critical heat exchangers located behind the grille. The agency is evaluating whether the design can contribute to damage that causes coolant or refrigerant leakage and potentially results in a loss of propulsion. The investigation follows complaints submitted to NHTSA's Office of Defects Investigation.

Open Grille Apertures May Expose Heat Exchangers

NHTSA says the grille configuration can allow rocks and debris to pass through and strike the hybrid inverter radiator, air-conditioning condenser, or radiator. The agency states that such impacts can puncture these components, potentially leading to coolant or refrigerant leakage and a resulting loss of propulsion. The Defect Petition similarly identifies the absence of a protective screen between the grille and the vehicle's heat exchangers as a potential contributor to damage. The concern is particularly significant because damage to cooling-system components can affect vehicle operation rather than being limited to cosmetic or minor mechanical issues. The United States investigation is therefore examining whether the design represents a safety-related defect.

Defect Petition Cites 13 Complaints

The Defect Petition cites 13 complaints received by NHTSA's Office of Defects Investigation concerning the alleged issue. Those complaints prompted the agency to open the petition for further evaluation rather than establishing a final defect determination. NHTSA's review will assess whether the reported condition is sufficiently connected to the vehicle design and whether additional regulatory action is warranted. The investigation covers vehicles from model years 2024 through 2026, encompassing both Grand Highlander and Grand Highlander Hybrid versions. As the United States regulator evaluates the petition, the findings could determine whether the agency grants or denies the request and whether further investigation or corrective measures are necessary.

Investigation Will Determine Next Regulatory Action

The current action does not represent a final finding that the Grand Highlander grille design is defective. Instead, NHTSA is opening the Defect Petition to determine whether it should be granted or denied based on the evidence available to the agency. The review will consider the reported complaints and the potential relationship between the open grille apertures, debris intrusion, heat-exchanger damage, fluid leakage, and propulsion loss. For affected vehicles in the United States, the outcome could clarify whether the reported condition requires additional safety action. Until the evaluation is completed, the investigation remains an assessment of the alleged defect rather than a confirmed recall or final regulatory conclusion.

Frequently Asked Questions

What is NHTSA investigating on the Grand Highlander?
NHTSA is evaluating whether the Grand Highlander's open grille design can allow rocks and road debris to damage critical heat exchangers, potentially causing fluid leakage and propulsion loss. The investigation covers 87,000 2024-2026 Grand Highlander and Grand Highlander Hybrid SUVs and follows 13 complaints cited in a Defect Petition. The agency is specifically assessing whether the lack of a protective screen behind the grille contributes to the reported condition. NHTSA has not made a final defect determination and is reviewing the petition to decide whether it should be granted or denied.