2002 Toyota Highlander Problems

What owners report

Owners of this model year most often write about the driver's side sun visor, which loses its friction and drops into the driver's line of sight; this dominates the visibility category and shows up from very low mileage. Second most common are reports of unintended acceleration or engine racing while the brake is applied, followed by engine coolant and head gasket leaks, brake light circuits that stop working, and transmission failure past 100,000 miles.

1. 1
   Visibility (wipers, defrost, mirrors)

   Sun visor drops into driver's view

   • 129 complaints (43%)
   • median 60,615 mi at 6.6 yrs old (88 state mileage)
   • owner-quoted repair $663 (median of 34 quotes)
   • filed 2004–2017

   The driver's side visor stops holding its stored position and swings down on its own, often over bumps or while braking, blocking part of the view through the windshield. Several owners describe holding it up, taping it in place, or removing it. Complaints say dealers quoted several hundred dollars for a replacement visor assembly, with the HomeLink-equipped version costing the most, and that no repair short of replacement was offered. Reported from as little as a few thousand miles up to about 120,000 miles, with many complaints filed between 40,000 and 70,000 miles.

   2 related service bulletins

   What to check: Push the driver's visor through its full range and let go — it should hold at every position. Ask whether the visor has been replaced and confirm the cost of a replacement if it has not.

   2 excerpts from owner complaints in NHTSA records

   “1. Regular driving causes the issue which seems to be due to poor product design. 2. The driver side sun visor does not stay in the upright position ever, and continuously blocks my clear view of the road. 3. The Toyota dealer was informed and they did nothing to fix their inferior product. I have to purchase a replacement sun visor.”

   NHTSA complaint #10278741, filed 2009-07, 30,000 miles

   “The driver side sun visor (w/ lighted mirror and homelink) on my 2002 Toyota Highlander will not stay up and drops down when driving which is a serious hazard. I understand that this is a very common problem with this vehicle and the cost for only the replacement part is over $700.00. It is obviously a design issue and serious hazard that Toyota will not address.”

   NHTSA complaint #10224862, filed 2008-04, 65,000 miles
2. 2
   Vehicle speed control

   Engine races or surges while braking

   • 37 complaints (12%)
   • median 64,874 mi at 7.1 yrs old (29 state mileage)
   • 11 mention a crash, fire or injury
   • filed 2002–2018

   Complaints describe the engine revving or the vehicle surging forward while the driver is already on the brake, sometimes at parking-lot speeds and sometimes at highway speed, in a few cases ending in a collision. Owners report having the throttle body and linkage checked, and one complaint notes the dealer attributed the event to the floor mat. In several accounts the vehicle could only be stopped by shifting to neutral or shutting off the engine. Spread from a few thousand miles to over 100,000 miles, with several reports in the 30,000 to 60,000 mile range.

   1 related service bulletin

   What to check: Ask whether the accelerator pedal sensor or throttle body has been inspected or replaced, and test that the pedal returns freely and the floor mat cannot slide under the pedals.

   2 excerpts from owner complaints in NHTSA records

   “After only having my new 2002 Toyota Highlander for approx. 8 months, the accelerator in the car stuck and I ended up running into a car. I complained to Toyota and had the dealer look at the car numerous times, but they kept telling me there was nothing wrong. Well 8 years later and they still haven't recalled my car, even though they have other years.”

   NHTSA complaint #10320349, filed 2010-03, 10,000 miles

   “Sometime in 2006, my 2002 Toyota Highlander experienced unintended acceleration. I was standing on the brake to make the car stop and it wouldn't. I pulled into a parking lot through the car into neutral, hit the brake, then through it into park while it was still moving. I called jiffy lube who just had performed an oil change. They sent a technician over to look at it. When I started the car for the tech the engine continued to race. We both looked to see if there was something stuck under the accelerator. There was not. …”

   NHTSA complaint #10319653, filed 2010-03, 50,000 miles
3. 3
   Engine cooling

   Coolant leaks and head gasket failure

   • 17 complaints (6%)
   • median 104,600 mi at 9.1 yrs old (16 state mileage)
   • 1 mention a crash, fire or injury
   • owner-quoted repair $5,500 (median of 6 quotes)
   • filed 2004–2015

   Owners describe overheating, coolant loss, and coolant seeping from the rear of the engine near the intake manifold. In several complaints the diagnosis was a failed head gasket, and some report stripped head bolt threads or oil sludge leading to a recommendation to replace the engine. Complaints mention repair estimates in the thousands of dollars. Mostly reported between about 55,000 and 120,000 miles, with cooling system checks often noted after several years of use.

   1 related service bulletin

   What to check: Check the coolant level and look for crusty residue or a sweet smell at the back of the engine, and ask whether the head gasket has been replaced or the cooling system pressure-tested.

   2 excerpts from owner complaints in NHTSA records

   “I noticed coolant leaking from underneath the plastic into intake manifold in the rear of the engine. I brought it in for repair and the mechanic said he noticed a large piece of foam rubber between the intake manifold and the engine block and head.the leak was behind the foam piece. The only option to discover the source of this leak was to remove the plastic intake manifold, which the mechanic did. …”

   NHTSA complaint #10281457, filed 2009-08, 56,000 miles

   “My 2002 Toyota Highlander v6 broke down on the side of the road. I had it towed to the Toyota dealership where they informed me that oil sludge has clogged my engine and I would have to have it replaced to the tune of $6000. I was shocked because I always got my oil changed well before the suggested 7500 mile mark. I did some research online and found out my car was part of a recall and class action suit. They never sent a recall notice. We purchased the car when it was 2 years old. …”

   NHTSA complaint #10328086, filed 2010-04, 110,000 miles
4. 4
   Electrical system

   Rear brake light stops working

   • 14 complaints (5%)
   • median 100,000 mi at 8.4 yrs old (13 state mileage)
   • 3 mention a crash, fire or injury
   • filed 2004–2014

   Complaints describe one rear brake light, usually the passenger side, failing to illuminate even after bulb replacement and contact cleaning. Owners report repeat visits to the dealer and socket or lamp assembly replacement attempts, and some say the light works only intermittently. Several owners link the problem to being rear-ended by another driver who could not see the brake lights. Typically reported between about 70,000 and 120,000 miles.

   What to check: With a helper, press the brake pedal and confirm all three rear brake lights illuminate, then wiggle the lamp housings to see whether the light cuts out.

   2 excerpts from owner complaints in NHTSA records

   “The left brake lights on my 2002 Toyota Highlander limited edition 4 wheel drive do not work. I changed the bulbs and they still do not work. I have researched possible causes and found hundreds of other consumers have had the same problems. This is a dangerous defect in that it arose suddenly, for no reason, and compromises the safety of the vehicles ability to warn other drivers that the car is braking. I am disappointed that Toyota has not recalled the car for what appears to be a significant malfunction.”

   NHTSA complaint #10394356, filed 2011-04, 120,000 miles

   “My passenger side brake light is intermittent at best. Replaced bulbs many times, cleaned contacts, etc...but no help.on-going problem . Was rear-ended due to this exact problem. Driver side brake light fine...it is always passenger side. Many complaints about this same exact issue on-line.”

   NHTSA complaint #10659709, filed 2014-11, 120,000 miles

Buying note. These reports concentrate on small parts and wear items rather than anything a recall addresses, so a careful test of the visor, brake lights, and transmission behavior on a test drive tells you a lot. Ask for maintenance records on the cooling system and transmission, since several complaints involve engine and gearbox work at higher mileage.

Summary written with AI from a sample of 60 NHTSA complaints for this model year (picked at random, with complaints that state a mileage and recent ones taken first), then checked automatically against the source records. Where a problem shows a complaint count, every complaint for this model year was matched with fixed keyword rules (written with AI and tested against the sample), and the mileage, age and repair figures are calculated from those complaints; owners' figures are as stated, not verified. Other counts refer to the sample. The excerpts come from NHTSA's public complaint records and are unverified; capitalisation is normalised, NHTSA staff notes are removed, and shortened text ends with “…”. Something wrong? Request a correction.