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.
2007 Toyota Highlander Hybrid Recalls
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.
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.