2006 Toyota Highlander Hybrid: headlights failing or too dim

Filed Feb 24, 2017 · Lights · 90,000 miles · MS

My 2006 highlander hybrid has burn marks on the headlight lens where the daytime running lights have gotten so hot that they actually melt the plastic on the inside of the headlight lens. This has reduced my visibility when driving at night and I would imagine that if it is getting hot enough to melt the headlight lens it creates a fire hazard as well. When I first noticed the issue, it didn't create a noticeable difference in driving visibility but as the problem gets worse and the spot gets larger there is a noticeable difference. If I am driving in an area without city lighting it is very hard to see with the lo-beams on and driving with the hi-beams on poses a danger to oncoming traffic of blinding them and causing them to crash into me or run off the road. The daytime running lights is something that the consumer cannot turn off and it is obvious from internet forums that this isn't an issue that is limited to my vehicle. It has been a well-documented problem for this model year highlander. I have opened a case with toyota headquarters and expressed my concerns to them personally but they have refused to rectify the situation. In my opinion, this shows not only a lack of support to their customers who pay hard-earned money for their vehicles but a lack of respect for the safety and lives of not only their customers but all of the individuals who share the roads with these vehicles. I am turning to the federal safety agency in the hopes of finally having my voice and the voice of the many other highlander owners in a similar situation heard and something done about this situation. Thank you in advance for any help that you can render!

Filed Nov 5, 2016 · Lights · 160,000 miles · CA

Front headlight on both right and left side burnt out, in doing so the outside lens was burned with a quarter size white spot. Plastic lens was melted.

Filed Mar 12, 2015 · Lights · 126,250 miles · IL · fire

Tl* the contact owns a 2006 toyota highlander hybrid. The contact discovered that the passenger side headlight lens and high beam bulb melted. As a result, the high beam lights were inoperable. The vehicle was taken to an independent mechanic who diagnosed that the failure was due to excessive electrical power traveling to the headlight assembly and the light assembly needed to be replaced. The vehicle was not repaired. The manufacturer was notified of the failure. The failure mileage was 126,250.

Filed Jun 24, 2014 · Lights · 86,000 miles · CA

Both driver and passenger headlights are melted, burned and grey in front of the daytime running light bulbs. Google search indicates that it is a fairly common issue. Called toyota and was told that there was nothing they would do to correct the issue.

Filed Mar 21, 2012 · Lights · 95,000 miles · MI · fire

Tl* the contact owns a 2006 toyota highlander hybrid. The contact stated that he driver and passenger side plastic headlight covers were melted. The vehicle was equipped with daytime running lights. The vehicle was taken an authorized dealer who stated there was not a defect found in the vehicle. The regional manager also inspected the vehicle. The vehicle was not repaired. The manufacturer was notified of the problem. The approximate failure mileage was 95,000.

Filed Nov 14, 2011 · Lights · 50,000 miles · CA

Both front headlight casings melted after using "brights".

Filed Jul 22, 2011 · Lights · 58,000 miles · WA

Tl* the contact owns a 2006 toyota highlander hybrid. The contact stated that the headlights lens was melted. The vehicle was inspected by the dealer who advised that the 3m plastic could have caused the failure. The plastic was removed from the lens and the vehicle was further inspected where there were no electrical failures found. The investigation concluded that the light bulb was defective. The manufacturer was contacted and they denied the claim. The failure mileage was approximately 58,000. Updated 10/12/11*lj updated 3/22/12

Filed May 13, 2011 · Lights · 75,000 miles · NJ

The headlamp covers on my 2006 toyota highland hybrid show significant melting exactly where the day lights shine through the plastic. This is definitely a defect in the materials, as the lights cannot be turned off by the driver. The vehicle has just 75000 miles, & the lens covers & bulbs are the original equipment. The dealer refused to correct this without approval from toyota. Toyota refuses to acknowledge that this is a defect and will not replace the lamps and/or the lens covers. I believe this is a safety hazard, as others have reported fires started by the overheated lenscovers. Another hazard is that as the lenses further deteriorate, they will allow water and moisture to seep in, increasing the risk of an electrical short. Although the warranty has expired, I feel that toyota should be admitting that this is a safety issue and a mfg defect, and replace the light units. Instead, toyota representatives have repeatedly stated that they haven't heard of this problem before, and will not take any corrective action.

Filed Apr 18, 2011 · Lights · CA

The headlight bulb on 2006 toyota highlander hybrid is so hot that it has discolored and slightly melted the lens cover. This plastic gets so hot that to be a safety hazard that could cause burns to individuals that might come in contact with the lens and/or the spuer heated lens plastic could become a fire hazard.

Filed Mar 9, 2011 · Lights · 57,000 miles · NH · fire

Tl* the contact owns a 2006 toyota highlander hybrid. The contact stated that the front headlamp covers were melting abnormally and causing the bulbs to blow. The dealer advised the contact to call the manufacturer but when contacted, the manufacturer offered no assistance. The vehicle was not repaired. The current and failure mileage was approximately 57,000.

Filed Jan 6, 2011 · Lights · 60,000 miles · NY

Lens is melting in front of day time running lite bulbs on both left & right sides of my 2006 toyota highlander hybrid.concerned this could cause fire as this is also the high beam lite. If left on accidently these could become very hot as the halogen bulbs will actually melt glass.

Filed Dec 20, 2010 · Lights · 83,000 miles · CA

Plastic headlight lenses are melting directly over the daytime running light (drl) halogen bulbs on both sides. The lights are the same as the 'brights' but should be at 50% power when used as drl's. Dealer informs me that they have never had this complaint and cannot find any other instances on-line or in their database, but there are several that I found within a few minutes of searching. At this point, it is only covered under the 36,000 mile warranty, but as this is a significant defect in either the plastic lens covering or in the bulb itself (running too hot) or in the drl relay that should be at 1/2 power, I would like to submit this for your consideration