- Toyota is recalling more than 550,000 Highlander and Highlander Hybrid vehicles due to a second-row seat back locking defect.
- Dealers will replace recliner return springs in the seat back assembly at no cost to owners.
The Toyota Motor Engineering & Manufacturing division has announced the Toyota Highlander seat back recall affecting 2021–2024 Highlander and Highlander Hybrid models in the United States. According to safety authorities, approximately 550,007 vehicles may have second-row seat backs that fail to lock properly during seat adjustment. If the locking mechanism does not fully engage, the seat back may move unexpectedly, increasing the potential safety risk for occupants during vehicle operation or sudden maneuvers.
Cause of the Seat Recliner Locking Issue
Investigators explained that the second-row seating system relies on recliner assemblies that allow the seat backs to unlock, adjust angle, and then lock securely into position. In the affected vehicles, a design change introduced by a supplier failed to properly account for the balance of forces between the locking spring and the return spring. This imbalance, combined with the orientation of the return spring and clearance between the recliner guide and ratchet mechanism, may prevent the recliner teeth from fully engaging while adjusting the seat back.
Supplier Component and Corrective Action
The rear seat frame sub-assembly used in the affected vehicles was supplied by Toyota Boshoku Indiana. As part of the remedy for the Toyota Highlander seat back recall, dealers will replace the return springs inside the seat back recliner assemblies to ensure proper locking performance. Toyota plans to notify vehicle owners by mail beginning April 20, and the repair will be carried out free of charge through authorized dealerships across the United States.
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