My brake actuator assembly failed while driving. The brakes stopped working. The cost to repair is over $3,000. This is a fairly common problem in the 2006 toyota highlander hybrid. In fact, Toyota extended the car's warranty to cover this issue, but it expired in 2017. The problem usually occurs once the car has approximately 150k miles which is likely outside the warranty period. This is extremely dangerous.
Toyota Highlander brake failure problems
98 of the 5,816 owner complaints about the Toyota Highlander describe brake failure, most of them for the 2006 model year.
- owner complaints
- 98
- worst model year
- 2006
- typical repair cost reported
- $3,000
- typical mileage
- 36,000
Is there a fix? There are 3 recalls for this area of the car. See below
By model year
Often reported together
ABS 11Sudden acceleration 5Check engine light 4No deployment 4Warning lights 3Spongy pedal 3Engine failure 3Stalling 2
Trouble codes mentioned
C1391 3C1256 3C1253 1C1252 1
What owners say
While depressing the brake pedal to come to a complete stop, the vehicle experienced a sudden loss of braking force, followed by a momentary forward surge/lunge before the friction brakes engaged.
Brake lag with loss of brakes during transition from regenerative to hydraulic friction braking. The vehicle braking system cuts out causing the vehicle to freely move forward which has caused near rear-end collisions with other vehicles, and loss of brakes at stop signs and crosswalks. The vehicle has been inspected four times at local dealership between June 1 and October 6, 2026. Brakes have been bled and recalibrated, actuator assembly has been replaced, and defect persists. Dealership has not been able to replicate the problem during their limited time with the vehicle. There are no warning lamps or messages and no other symptoms prior to each failure. Began noticing issue in May 2026. The issue appears to be similar to what is described in T-SB-0059-23 for the 2022 Toyota Highlander Hybrids (and Siennas) which is titled "Hybrid Regenerative Brake Transition Feeling Improvement" where there is a brake lag and momentary loss of braking sensation, and forward lurch/surge. Toyota has not issued a repair solution for the 2023 Highlander Hybrid, so there is no software calibration solution.
The contact owns a 2022 Toyota Highlander. The contact stated that while depressing the brake pedal, the brakes failed to respond causing the braking distances to be extended. The contact stated that the failure was intermittent but had occurred on several occasions almost causing a crash. The vehicle was taken to the local dealer on several occasions, but the cause of the failure was not yet determined. The manufacturer was notified of the failure. The failure mileage was 8,000.
The contact owns a 2021 Toyota Highlander. While driving 20 MPH uphill, the messages "Engine Failure," "Brake Failure," and "Pull Over to A Safe Place, See Owner's Manual" were displayed, and several unknown warning lights illuminated. The contact turned off and restarted the vehicle, but the failure persisted. After a second restart, the message "See Dealer" was displayed with the check engine warning light illuminated. After a third restart, the vehicle was driving rough while the accelerator pedal was depressed. The vehicle was taken to the dealer. The manufacturer was notified of the failure by phone. The failure mileage was approximately 123,000.
The contact owns a 2019 Toyota Highlander. The contact stated that while attempting to depress the brake pedal, the brakes failed to operate as intended. The contact stated that after taking the foot off the brake pedal, the brakes started working as intended. The vehicle was drivable. The vehicle was driven to the residence, and the contact researched and became aware that there were several owners who had the same failure. The failure mileage was 69,000.
2023 Toyota Highlander Hybrid Regenerative Brake Transition loss of brake pad pressure resulting in acceleration of the vehicle under downhill conditions. Have momentarily experienced the loss of braking frequently during braking when going downhill. This results in the vehicle gaining speed during this 1 or 2 second period before braking returns. In one case it allowed our car to get dangerously close to the vehicle ahead of us but fortunately I was able to push the brakes harder to prevent an accident but did require aggressive braking. Luckily no one was behind us which may have resulted in the person following us braking hard or possible hitting us. This was a known issue for previous year Toyota Highlander models and Toyota issued service bulletin T-SB-0059-23 which is stated to only be for model years 2020 - 2022. So, Toyota dealers say they do not have a fix that applies to the 2023 model. It has been indicated that the dealer is unaware if any action is being taken by Toyota to address this issue in the 2023 and later models. We have multiple people driving this vehicle and this sudden loss of braking power is very concerning. The loss of braking force occurs upon the transition from regenerative braking to standard hydraulic breaking. Below are words from the Toyota Technical Service notice concerning the problem. "Highlander Hybrid vehicles may be sensitive to the momentary transition from regenerative braking to hydraulic braking under certain driving conditions, such as while driving downhill, or turning with light brake pedal application. The brake actuator control module can be updated to improve brake feeling for this condition. Follow the Repair Procedure in this bulletin to address this condition."
I am reporting a serious safety defect involving the rear brake system of my 2021 Toyota Highlander, purchased from Penn Toyota (Glen Cove, NY). The dealership represented the vehicle as “Toyota Certified” and indicated that it passed all safety inspections. On November 15, 2025, I discovered that the rear brake rotors and pads were in extremely unsafe condition, showing severe corrosion, deep pitting, uneven pad wear, and structural deterioration. This damage clearly developed over a long period of time and indicates that the vehicle could not have passed a legitimate safety inspection at the time of sale. The rear brakes had to be replaced immediately to prevent potential brake failure. After replacing the rear rotors and pads, the vehicle passed the New York State Inspection on the same day, proving that the previous brake condition was unsafe and improperly inspected. This raises concerns of: Brake safety failure Improper or falsified dealership inspection Risk of reduced stopping power Potential loss of vehicle control I am submitting photos, the repair invoice, and the inspection result that confirmed the brakes were unsafe prior to repair.
Entering the freeway a mile from home the car would not properly excellerate, only reachind 40 mph before exiting the freeway in favor backroads to my appointment. Shaking back and forth while driving, exacerbated when braking and coming to stop, I needed to put the car into neutral to calm down the shaking while waiting for the light to change. I just went through experiencing a brake failure and reporting of that to this Agency and now see another of many defects associated with the 2020-2022 Toyota Highlanders and Siennas Toyota is not addressing through Recalls as they should be, and further frustrated this Agency has or chooses to have no means by which to enforce Toyota's responsibility to the public
I was on the interstate driving about 72 mph when the car just shut off all the dash lights came on and the dash it said check hybrid system I had no brakes or steering I got it off the road turned it off and back on again it started up and I drove it home but the dash still displayed check hybrid system , a week later I get in it to go to work and there’s an alarm that won’t cut off and the abs , traction control and brake light and warning light and tire pressure light are all on and the brakes are hard and there’s a weird noise coming from somewhere when u push on the brake and it says check VSC system on the dash now
Related recalls
Service brakes, hydraulic: power assist: vacuum
- What is wrong
- Toyota Motor Engineering & Manufacturing (Toyota) is recalling certain 2018 Toyota Camry and Highlander vehicles, 2017 Toyota Sienna and Tacoma vehicles and 2017 Lexus RX350 vehicles. During the manufacturing process, the oil galley in the rotor for the brake booster vacuum pump assembly may have been improperly machined possibly resulting in a sudden loss of brake assist.
- Risk
- A sudden loss of braking assist can increase the risk of a crash.
- Remedy
- Toyota will notify owners, and dealers will replace the brake booster vacuum pump, free of charge. The recall began on May 9, 2018. Owners may contact Toyota customer service at 1‑888‑270‑9371, or Lexus customer service at 1‑800‑255‑3987. Toyota's numbers for this recall are J0K/JLD.
Recall number 18V211000 · Recall details
Service brakes, hydraulic: foundation components: master cylinder
- What is wrong
- Toyota is recalling certain model year 2005-2006 avalon, model year 2004-2006 highlander, model year 2004-2006 lexus rx, and model year 2006 lexus gs and is vehicles. Brake fluid containing polymers is used that acts as lubricants for certain brake system components. If replacement brake fluid is used that does not contain such polymers, or that contains only small amounts, a part of the rubber seal located at the rear of the brake master cylinder may become dry, and the seal may curl during movement of the piston. If this occurs, a small amount of brake fluid could slowly leak from the seal into the brake booster.
- Risk
- A leak of brake fluid could lead to a change in brake pedal feel and overtime a degradation in braking performance increasing the risk of a crash.
- Remedy
- Dealers will replace the seal with a newly designed one. This service will be performed free of charge. The safety recall began on november 15, 2010. Owners may contact toyota at 1‑800‑331‑4331 and lexus at 1‑800‑255‑3987.
Recall number 10V499000 · Recall details
Service brakes, hydraulic: foundation components: master cylinder
- What is wrong
- Vehicle description: sport utiity vehicles. The reservoir filler cap of the brake master cylinder may induce a vacuum, introducing some air into the brake master cylinder reservoir. This could cause abnormal brake noise and increased pedal stroke when the brakes are applied.
- Risk
- The increased pedal stroke will lengthen the stopping distance of the vehicle, increasing the risk of a crash.
- Remedy
- Dealers will bleed the air from the brake lines and replace the reservoir filler cap. Owner notification began july 30, 2001. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact toyota at 1‑800‑331‑4331.
Recall number 01V228000 · Recall details
Questions about the Toyota Highlander brake failure
Which Toyota Highlander years have brake failure problems?
The model years with the most reports are 2006 (17 complaints), 2008 (11 complaints) and 2018 (7 complaints).
How much does it cost to fix brake failure on the Toyota Highlander?
Owners who mentioned a price put the repair at about $3,000 (median of 9 complaints that include a dollar amount). Costs vary with mileage, warranty and where the work is done.
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