failure of brakes after recall repair done in 2011 2005 Toyota Highlander Toyota NA case #1610150775 On Friday 10/14/2016 my son, a college freshman, told me he was experiencing braking issue and a “soft pedal” on his 2005 Toyota Highlander. When I sat in the car I was disturbed to find the pedal was more than soft it extended nearly the entire range before the last bit of pedal provided some but limited braking. I researched this problem and found recall information below, which describes the problem we are experiencing. I spoke with Toyota North America and was told to bring the car to the local Toyota Dealer Rosner Toyota in Fredericksburg VA. I was called and informed the recall was performed by Fairfax Toyota in 2011 and that the repair was not covered and would cost $1700. Surprised I asked how a failed recall repair, involving a safety system, was not covered and was told you will need to call Toyota North America. I called Toyota NA on Sat 10/15/2016 and was told I would be assigned a Case Manager and get a call on Monday form Toyota NA. On Monday I spoke with the Service Manager at Rosner who told me that he would need to ask the District Manager to approve the repair. Note: I learned that some recalls just replaced the seal in the master and others also replaced the booster – our vehicle only received the seal. I then got another call from the Service Manager at Rosner that the district manager declined the repair under the recall. All I could do is call back to Toyota NA… I did and was told Toyota’s position is “They will not repair the problem with the brakes even if it is the same failure as the recall service was done”. My position is: 1. The vehicle is unsafe and it is a direct result of the same problem in the braking system as reported in recall 10V499000. 2. If a dangerous condition reoccurs perhaps the recall repair was not done, done incorrectly or is a reoccurring problem. 3. The technician at Rosner reported brake fluid in the booster and hence the “seal” only recall repair is clearly in question. 4. The vehicle is inoperable and placed my son at risk – short of a catastrophic failure no braking system should have this failure mode. 5. Toyota should make this repair under the warranty policy – especially true since it is now clear that the repair was not the full booster replacement. 6. If Toyota does not respond to this complaint to the below by COB 10/18/2016 we will seek remedy in small claims court for the $1700 repair and damages resulting from loss of use. Please contact me regarding this matter. Richard Domikis 540-388-6588 Rosner Recall Number 10V499000 Recall Date 10/21/2010 Component SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:MASTER CYLINDER Summary 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. Consequence 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. What Owners Should Do DEALERS WILL REPLACE THE SEAL WITH A NEWLY DESIGNED ONE. THIS SERVICE WILL BE PERFORMED FREE OF CHARGE. THE SAFETY RECALL IS EXPECTED TO BEGIN DURING NOVEMBER 2010. OWNERS MAY CONTACT TOYOTA AT 1-800-331-4331 AND LEXUS AT 1-800-255-3987.