Service bulletin T-SB-0040-24 Rev1

A bulletin is a manufacturer's communication to its dealers, as NHTSA indexes it. The summary is NHTSA's. The document is the manufacturer's: read it at NHTSA. A bulletin is not a recall, and listing a model year does not mean every vehicle of it is concerned.

The communication, as NHTSA indexes it (as of 2026-10-19)
Type	Service bulletin
NHTSA id	11034823
Published by NHTSA	2026-07-08
Manufacturer's number	T-SB-0040-24 Rev1
Manufacturer's date	2026-06-25
Campaign id or software version	T-SB-0040-24 Rev1
NHTSA component	STRUCTURE:BODY

NHTSA's summary

Some 2020 – 2026 model year Highlander and Highlander Hybrid vehicles may exhibit a water leak from the roof rack attachment clips. This may be caused by the sealant in the roof channel obstructing the proper seating position for the clip gasket.

The document

The document is the manufacturer's. This site does not hold it. NHTSA files a document at one of these two addresses; we have not asked NHTSA which.

Components

Body and frame

Vehicles listed
TOYOTA HIGHLANDER	2020, 2021, 2022, 2023, 2024, 2025, 2026
TOYOTA HIGHLANDER HYBRID	2020, 2021, 2022, 2023, 2024, 2025, 2026 (the catalog's model; the bulletin names a series or trim of it)

Listing a model year does not mean every vehicle of it is concerned: the document says which.

Recalls for the same vehicles and component
2023574	2023-10-26. Structure
23V720000	2023-10-26. STRUCTURE:BODY:BUMPERS

A recall listed here may apply to some of the same vehicles. Only the manufacturer can say whether it applies to one vehicle.

Other bulletins for the same vehicles and component
T-SB-0086-25	2025-12-05. Service bulletin. Some 2020 – 2023 model year Highlander and Highlander Hybrid vehicles may exhibit a condition in which the Power Back Door (PBD) will not open or close and/or stops moving while opening or closing. A modified PBD unit assembly is available to address these conditions.
T-SB-0039-24 Rev2	2025-01-09. Service bulletin. The condition known as acid rain is caused by airborne chemicals or particles in the atmosphere, which mix with rainwater, nighttime dew, or high humidity to form acidic compounds. If these contaminants settle and remain on a painted vehicle surface, especially the horizonal areas of the hood, roof, and decklid, significant damage can occur. This damage is the result of actual etching of the paint and appears as pitting or water spots. As acid rain droplets on the vehicle surface evaporate, the concentration strength of the acid increases, causing deeper and more rapid damage. This evaporation and corrosive action also occur more rapidly on dark colored cars as direct sun heat increases. It is the dealer’s responsibility to protect and maintain the quality of the vehicle’s paint finish after receipt at the dealership prior to the first sale. In areas known for high frequency and/or concentration of acid rain, frequent vehicle washing during high heat or humidity periods will minimize the potential for paint damage caused by acid rain. It is further recommended that either reverse osmosis or deionized water be used to prevent water spotting.
T-SB-0038-24 Rev2	2025-01-09. Service bulletin. To prevent brake rotor rust from forming during transportation and storage, wheel film will be used instead of a cardboard type of anti-rust cover. The purpose of the wheel film is to shield the disc brake rotor from weather elements and initial rust before the vehicle is delivered to the customer. Consequently, the film should remain on the wheel for as long as possible.
T-SB-0035-24 Rev2	2025-01-09. Service bulletin. Acid rain results from rainwater or other airborne moisture that become acidic due to industrial chemical impurities in the atmosphere. If these acidic compounds settle on an exposed vehicle, especially the horizontal areas such as the hood, roof, and decklid, significant damage to the painted surfaces can occur. Acid rain damage can typically be identified on vehicles by the presence of stains on the paint surface that resemble hard water spots. Unlike water spots however, acid rain damage cannot be removed by regular washing procedures. Also, because acid rain can etch and soften the paint, normal buffing or polishing repair procedures should not be attempted. This can cause further damage and result in visible depressions in the paint surface. The following are the three major categories of acid rain damage: •Minor damage: requires only buffing to repair. •Moderate damage: usually requires neutralizing, color sanding, and buffing. •Severe damage: extending beyond 1/2 mil of clearcoat on a pearl, metallic, or solid color, requires neutralization, sanding, and repainting. In cases where acid rain damage is minor, neutralization and buffing with a liquid-type paint finessing product may provide an adequate repair. Only specially formulated products outlined in this bulletin should be used for that purpose. Unfortunately, other than minor damage, there is no simple method of determining the actual extent (depth) of acid penetration other than color sanding a representative affected area until there is no visible etching or depressions, followed by measuring the amount of paint removed with either a magnetic or digital-type film thickness gauge. The procedures in this bulletin are intended for use by qualified body/paint technicians and should not be attempted by inexperienced personnel. It is the dealer’s responsibility to protect and maintain the quality of the vehicle’s paint finish after receipt at the dealership prior to the first sale. Perform frequent vehicle washing, as often as daily, during high heat and humidity periods to minimize the potential for paint damage due to acid rain exposure. This is especially important in geographical areas known for high frequency and concentration of acid rain and industrial fallout.
T-SB-0061-23 Rev2	2025-01-09. Service bulletin. Toyota vehicles are currently protected with RapgardTM protective film designed to protect the horizontal painted surfaces. This material protects from acid rain, environmental fallout, and rail contamination. Follow the Removal Procedure in this bulletin to remove the RapgardTM protective film within 90 days from initial application.
T-SB-0062-23 Rev2	2025-01-09. Service bulletin. Vehicles may occasionally be subjected to contamination by airborne iron particles shed from railroad tracks, train wheels, exposure to heavy machinery facilities, grinding, welding, etc. This type of contamination can be identified by the presence of small, red or brown particles on the paint surface. These particles are often difficult to see on dark color paints but can be easily felt when brushing a hand across horizontal body surfaces such as the hood, roof, or deck lid. Follow the Repair Procedure in this bulletin to clean vehicles that may have been subjected to contamination by airborne iron particles such as rail dust during rail transportation or extended storage near industrial areas.
T-SB-0098-24	2024-11-08. Service bulletin. Some 2022 model year Avalon and Avalon Hybrid, 2022 – 2024 model year Camry, Camry Hybrid, Corolla, Corolla Hatchback, Corolla Hybrid, Highlander, Highlander Hybrid, Prius, Prius Prime, RAV4, RAV4 Hybrid, RAV4 Prime, and Venza Hybrid, 2023 – 2024 model year Crown, and 2024 model year Grand Highlander vehicles may exhibit a high-pitched noise coming from the front HVAC blower motor while operating the air conditioner or heater. This condition does not affect the operation of the vehicle, however, a heater cover has been developed to help reduce or potentially eliminate the noise.
T-TT-0751-24 Rev1	2024-11-06. Service bulletin. Some customers have expressed concern that the wireless functions of their Key Fob stop working. Key Fob LEDs will not turn ON, but engine starts with key held up against start button. Key battery voltage is confirmed OK and no DTC/RoB is found. This condition may occur if customer places Key Fob near wireless charger while phone is charging. When the key battery is removed and reinstalled, the Key Fob begins to operate normally.
T-SB-0055-24 Rev1	2024-09-07. Service bulletin. Some 2005 – 2024 Toyota vehicles that have undergone water intrusion may exhibit a condition in which a musty odor is present. Follow the procedures in this bulletin to remediate the odor and address this condition. The purpose of this Service Bulletin is to provide general guidelines and procedures for odor remediation. This Service Bulletin provides a guide on how to prepare and treat the interior of the vehicle for odor remediation. Refer to the applicable model and model year Repair Manual and the EPA (Environmental Protection Agency) website for the most up-to-date safety and precautionary guidelines. This Service Bulletin is to provide a general overview and direction for the odor remediation process.
T-SB-0039-24 Rev1	2024-09-07. Service bulletin. The condition known as acid rain is caused by airborne chemicals or particles in the atmosphere, which mix with rainwater, nighttime dew, or high humidity to form acidic compounds. If these contaminants settle and remain on a painted vehicle surface, especially the horizonal areas of the hood, roof, and decklid, significant damage can occur. This damage is the result of actual etching of the paint and appears as pitting or water spots. As acid rain droplets on the vehicle surface evaporate, the concentration strength of the acid increases, causing deeper and more rapid damage. This evaporation and corrosive action also occur more rapidly on dark colored cars as direct sun heat increases. It is the dealer’s responsibility to protect and maintain the quality of the vehicle’s paint finish after receipt at the dealership prior to the first sale. In areas known for high frequency and/or concentration of acid rain (see Figure 1), frequent vehicle washing during high heat or humidity periods will minimize the potential for paint damage caused by acid rain. It is further recommended that either reverse osmosis or deionized water be used to prevent water spotting.