My 2006 Highlander hybrid has burn marks on the headlight lens where the daytime running lights have gotten so hot that they actually melt the plastic on the inside of the headlight lens. This has reduced my visibility when driving at night and I would imagine that if it is getting hot enough to melt the headlight lens it creates a fire hazard as well. When I first noticed the issue, it didn't create a noticeable difference in driving visibility but as the problem gets worse and the spot gets larger there is a noticeable difference. If I am driving in an area without city lighting it is very hard to see with the lo-beams on and driving with the hi-beams on poses a danger to oncoming traffic of blinding them and causing them to crash into me or run off the road. The daytime running lights is something that the consumer cannot turn off and it is obvious from internet forums that this isn't an issue that is limited to my vehicle. It has been a well-documented problem for this model year highlander. I have opened a case with Toyota headquarters and expressed my concerns to them personally but they have refused to rectify the situation. In my opinion, this shows not only a lack of support to their customers who pay hard-earned money for their vehicles but a lack of respect for the safety and lives of not only their customers but all of the individuals who share the roads with these vehicles. I am turning to the NHTSA in the hopes of finally having my voice and the voice of the many other highlander owners in a similar situation heard and something done about this situation. Thank you in advance for any help that you can render!

- Petal, MS, USA

Front headlight on both right and left side burnt out, in doing so the outside lens was burned with a quarter size white spot. Plastic lens was melted.

- Santa Cruz, CA, USA

The contact owns a 2006 Toyota Highlander hybrid. The contact discovered that the passenger side headlight lens and high beam bulb melted. As a result, the high beam lights were inoperable. The vehicle was taken to an independent mechanic who diagnosed that the failure was due to excessive electrical power traveling to the headlight assembly and the light assembly needed to be replaced. The vehicle was not repaired. The manufacturer was notified of the failure. The failure mileage was 126,250.

- Mokena, IL, USA

Both driver and passenger headlights are melted, burned and grey in front of the daytime running light bulbs. Google search indicates that it is a fairly common issue. Called Toyota and was told that there was nothing they would do to correct the issue.

- Ventura, CA, USA

The contact owns a 2006 Toyota Highlander hybrid. The contact stated that he driver and passenger side plastic headlight covers were melted. The vehicle was equipped with daytime running lights. The vehicle was taken an authorized dealer who stated there was not a defect found in the vehicle. The regional manager also inspected the vehicle. The vehicle was not repaired. The manufacturer was notified of the problem. The approximate failure mileage was 95,000.

- Jenison, MI, USA

Both front headlight casings melted after using "brights".

- Canyon Country, CA, USA

The contact owns a 2006 Toyota Highlander hybrid. The contact stated that the headlights lens was melted. The vehicle was inspected by the dealer who advised that the 3M plastic could have caused the failure. The plastic was removed from the lens and the vehicle was further inspected where there were no electrical failures found. The investigation concluded that the light bulb was defective. The manufacturer was contacted and they denied the claim. The failure mileage was approximately 58,000. Updated 10/12/11 updated 3/22/12

- Shoreline, WA, USA

The headlamp covers on my 2006 Toyota highland hybrid show significant melting exactly where the day lights shine through the plastic. This is definitely a defect in the materials, as the lights cannot be turned off by the driver. The vehicle has just 75000 miles, & the lens covers & bulbs are the original equipment. The dealer refused to correct this without approval from Toyota. Toyota refuses to acknowledge that this is a defect and will not replace the lamps and/or the lens covers. I believe this is a safety hazard, as others have reported fires started by the overheated lenscovers. Another hazard is that as the lenses further deteriorate, they will allow water and moisture to seep in, increasing the risk of an electrical short. Although the warranty has expired, I feel that Toyota should be admitting that this is a safety issue and a mfg defect, and replace the light units. Instead, Toyota representatives have repeatedly stated that they haven't heard of this problem before, and will not take any corrective action.

- Blairstown, NJ, USA

The headlight bulb on 2006 Toyota Highlander hybrid is so hot that it has discolored and slightly melted the lens cover. This plastic gets so hot that to be a safety hazard that could cause burns to individuals that might come in contact with the lens and/or the spuer heated lens plastic could become a fire hazard.

- Poway, CA, USA

The contact owns a 2006 Toyota Highlander hybrid. The contact stated that the front headlamp covers were melting abnormally and causing the bulbs to blow. The dealer advised the contact to call the manufacturer but when contacted, the manufacturer offered no assistance. The vehicle was not repaired. The current and failure mileage was approximately 57,000.

- Alton Bay, NH, USA

Lens is melting in front of day time running lite bulbs on both left & right sides of my 2006 Toyota Highlander hybrid.concerned this could cause fire as this is also the high beam lite. If left on accidently these could become very hot as the halogen bulbs will actually melt glass.

- Hoosick Falls, NY, USA

Plastic headlight lenses are melting directly over the daytime running light (drl) halogen bulbs on both sides. The lights are the same as the 'brights' but should be at 50% power when used as drl's. dealer informs me that they have never had this complaint and cannot find any other instances on-line or in their database, but there are several that I found within a few minutes of searching. At this point, it is only covered under the 36,000 mile warranty, but as this is a significant defect in either the plastic lens covering or in the bulb itself (running too hot) or in the drl relay that should be at 1/2 power, I would like to submit this for your consideration

- Sunland, CA, USA

The contact owns a 2006 Toyota highlander hv. She noticed that there was a round circle around the lens area on both headlights. The vehicle was taken to an authorized dealer where she was informed that the lens on both headlights were melting. The vehicle was not repaired. The failure mileage was 51,000 and the current mileage was 51,876.

- Kirtland, OH, USA

I own two Highlander hybrids, 2006. One was purchased in September 2005, the other in September 2006. On the older of the two, in front of the daytime running lights I have exactly the same melted plastic shown in multiple pictures I found online. On the newer one, you can see imperfections forming on one side, and a smaller fully melted area in the other. I am in touch with Toyota and they are offering new lens parts and I must pay labor. I pushed back and told them I believe this is a manufacturers defect, and that it should be covered by both my original warranty and the nearly $2000 Toyota assurance extended warranty. This defect will ultimately obscure the light and make my vehicle harder to see on the road, which presents a safety hazard. As the problem progresses, a hole will form in the lens allowing children to touch the extremely hot halogen lights, potentially resulting in serious burns. It will also expose the headlamps to damage from rocks that would have been blocked by the melted part. From the two Highlander hybrid 2006's I have, in central California's mediterranean climate it appears that the problem becomes apparent between 40,000 and 60,000 miles.

- Sacramento, CA, USA

I own two Highlander hybrids, 2006. One was purchased in September 2005, the other in September 2006. On the older of the two, in front of the daytime running lights I have exactly the same melted plastic shown in multiple pictures I found online. On the newer one, you can see imperfections forming on one side, and a smaller fully melted area in the other. I am in touch with Toyota and they are offering new lens parts and I must pay labor. I pushed back and told them I believe this is a manufacturers defect, and that it should be covered by both my original warranty and the nearly $2000 Toyota assurance extended warranty. This defect will ultimately obscure the light and make my vehicle harder to see on the road, which presents a safety hazard. As the problem progresses, a hole will form in the lens allowing children to touch the extremely hot halogen lights, potentially resulting in serious burns. It will also expose the headlamps to damage from rocks that would have been blocked by the melted part. From the two Highlander hybrid 2006's I have, in central California's mediterranean climate it appears that the problem becomes apparent between 40,000 and 60,000 miles. Related ODI numbers for my other 2006 highlander, which is a year older and has a more pronounced problem due to the additional time with the daytime running lights on: 10292093 multiple complaints for the same problem exist on the highlander 2005 model complaint filed 20070816, crownsville, md (resulted in fire in headlamp) complaint filed 20060712, setauket, NY. Multiple complaints for the same problem exist on the highlander 2004 model complaint filed 20050409, medway MA complaint filed 20081222, quincy, wa complaint filed 20071203, sparks,

- Sacramento, CA, USA