Two of the main control modules for the hybrid drive system are the Inverter Module and the Intelligent Power Module (IPM), which is located inside the Invertor Module. The IPM can operate at temperatures high enough to damage its electrical solder connections. Damaged solder joints can result in illumination of warning lights, various drivability concerns, and possible stalling of the hybrid drive system. Dealers will replace the IPM on affected vehicles to correct this concern.
2006 Toyota Highlander Hybrid Recalls
The amount of adhesive applied between the inner and outer parts of the crankshaft pulley may be inadequate. If this is the case, the outer ring may become misaligned and/or not properly rotate with the inner ring, causing an abnormal noise and/or illumination of the Check Engine Light. In some cases, the power steering belt could come off resulting in a loss of power steering assist, increasing the risk of a crash. Dealers will inspect the crankshaft pulley and replace it if necessary.
A module inside the hybrid drive inverter module may contain inadequately soldered transistors. These solder joints could fail under high electrical loads, resulting in illumination of various dashboard warning lights, drivability concerns, and/or engine stalling. If the vehicle were to stop unexpectedly, this would increase the risk of a crash. Owners will be notified in July 2011 if their vehicle is involved in this recall. They will received a second notice when parts become available. Dealers will inspect the hybrid inverter module production number to determine if the inverter contains the suspect transistors. They will replace any affected modules.
The floor carpet cover may interfere with the accelerator pedal if its forward retention clip is not installed properly. As a result, the throttle can become stuck in a partially open position, increasing the risk of a crash. Dealers will replace the carpet cover with a newly designed one. No owner notification schedule has been provided at this time.
These vehicle were sold without the required load carrying captivity modification label. Dealers will mail the corrected label to vehicle owners. Owners have the option of requesting that the dealer install the label. This recall is expected to begin on May 27, 2010.
The load carrying capacity modification label may be missing from the vehicle. This information provides maximum load carrying weights as well as information about required tires and wheels. If not present, an inappropriate load may be carried in the vehicle, increasing a safety risk. Toyota has supplied customers with a new label to affix to the vehicle. This recall began on August 18, 2009.