NHTSA ID Number: 11021719
Manufacturer Communication Number: T-SB-0111-24 Rev1
TSB/Document Date: 2025-08-08
Summary
Some 2024 – 2025 model year Grand Highlander and Grand Highlander Hybrid
vehicles may exhibit an abnormal fluttering and/or vibration across the rear-center section of the hood. This phenomenon is most notable on darker color vehicles. However, this condition may be noticed on the subject vehicles regardless of the paint color.
T-SB-0111-24
Rev1
December 4, 2024
Abnormal Fluttering and/or Vibration Across RearCenter Section of Hood
Service
Category
Vehicle Exterior
Section
Exterior Panels/Trim
Market USA and
Mexico
Applicability
YEAR(S)
MODEL(S)
2024 - 2025
Grand Highlander, Grand
Highlander HV
ADDITIONAL INFORMATION
REVISION NOTICE
July 15, 2025 Rev1:
Applicability has been updated to include 2025 model year Grand Highlander and
Grand Highlander Hybrid vehicles.
Any previous printed versions of this bulletin should be discarded.
Introduction
Some 2024 – 2025 model year Grand Highlander and Grand Highlander Hybrid vehicles may
exhibit an abnormal fluttering and/or vibration across the rear-center section of the hood. This
phenomenon is most notable on darker color vehicles. However, this condition may be noticed on
the subject vehicles regardless of the paint color. Follow the Repair Procedure in this bulletin to
address this condition.
© 2025 Toyota Motor Sales, USA
Page 1 of 7
T-SB-0111-24
Rev1
December 4, 2024
Page 2 of 7
Abnormal Fluttering and/or Vibration Across Rear-Center Section of Hood
Warranty Information
For USA Market
OP CODE
DESCRIPTION
TIME
OFP
T1
T2
BD2422
Fill Hood Cavity with Expanding Foam
1.5
53301-0E270
9B
99
APPLICABLE WARRANTY
This repair is covered under the Toyota Basic Warranty. This warranty is in effect for 36 months
or 36,000 miles, whichever occurs first, from the vehicle’s in-service date.
Warranty application is limited to occurrence of the specified condition described in
this bulletin.
For Mexico Market
OP CODE
DESCRIPTION
TIME
OFP
T1
T2
BD2422
Fill Hood Cavity with Expanding Foam
1.5
53301-0E270
9B
99
APPLICABLE WARRANTY
This repair is covered under the Toyota Basic Warranty. This warranty is in effect for 36 months
or 60,000 kilometers, whichever occurs first, from the vehicle’s in-service date.
Warranty application is limited to occurrence of the specified condition described in
this bulletin.
© 2025 Toyota Motor Sales, USA
T-SB-0111-24
Rev1
December 4, 2024
Page 3 of 7
Abnormal Fluttering and/or Vibration Across Rear-Center Section of Hood
Parts Information
PART NUMBER
PART NAME
QTY
90467-A0003
Clip (for Hood Insulator)
9
NOTE
The original hood insulator clips may become damaged during the removal process. Replace any of the
damaged hood insulator clips with NEW clips.
Required Tools & Equipment
REQUIRED TOOLS & MATERIAL
QTY
3MTM Manual Cartridge Applicator, 08571 (or Equivalent)
1
3MTM Flexible Foam 08463, Urethane, 200 mL Cartridge (or Equivalent)
4
3MTM 8193 Mixing Nozzle (or Equivalent)
8
Disposable Plastic Cover
As Needed
Nitrile Gloves
As Needed
Painter’s Tape
1 Roll
Disposable Shop Towels
1 Roll
Borescope*
1
* A borescope may be helpful in performing the procedure but is not necessary.
NOTE
Disposable plastic cover MUST cover the entire engine bay, fenders, and the lower quarter of the
windshield. Since plastic covers come in various sizes and shapes, the quantity of plastic covers needed
for this repair will vary.
© 2025 Toyota Motor Sales, USA
T-SB-0111-24
Rev1
December 4, 2024
Page 4 of 7
Abnormal Fluttering and/or Vibration Across Rear-Center Section of Hood
Repair Procedure
1. Confirm the condition exists.
Does the vehicle exhibit a condition with an abnormal fluttering and/or vibration across the
rear-center section of the hood?
YES — Continue to step 2.
NO — This bulletin does NOT apply. Continue diagnosis using the applicable
Repair Manual.
2. Open the hood and prop normally.
Figure 1. Hood Securely Opened
3. Protect the engine bay, cowl, and lower portion of windshield from any potential drips from the
foam application by covering with disposable plastic covers.
Figure 2. Protected Engine Bay
Figure 3. Protected Fender and Windshield
© 2025 Toyota Motor Sales, USA
T-SB-0111-24
Rev1
December 4, 2024
Page 5 of 7
Abnormal Fluttering and/or Vibration Across Rear-Center Section of Hood
Repair Procedure (continued)
4. Remove the hood insulator by carefully removing the nine hood insulator clips.
Refer to TIS, applicable model and model year Repair Manual.
2024 – 2025 Grand Highlander and Grand Highlander HV:
Vehicle Exterior – Door / Hatch – Hood – Disassembly
NOTE
Perform step 1 ONLY.
5. Gather all the materials and stage near
the vehicle.
Figure 4. Stage Materials Near the Vehicle
6. Install the mixing nozzle and foam cartridge
in the applicator gun.
Figure 5. Assembled Applicator
© 2025 Toyota Motor Sales, USA
T-SB-0111-24
Rev1
December 4, 2024
Page 6 of 7
Abnormal Fluttering and/or Vibration Across Rear-Center Section of Hood
Repair Procedure (continued)
7. Insert the mixing nozzle tip at an angle into
each of the accessible openings in the
hood as shown in figures 6 – 7.
Figure 6. Nozzle Inserted at an Angle
Fill cavities with expanding foam until the
foam is touching both the inner and outer
hood panels. The use of a borescope may
be helpful to ensure foam expansion but is
not required.
In larger openings, use a sweeping motion
to maximize coverage, as shown in this
Example Video.
Black stickers covering some holes will
need to be removed and replaced once the
expanding foam has cured.
NOTE
In some cases, it may be necessary to pause and replace the nozzle before proceeding to the
next cavity.
The expanding foam will cure extremely fast.
Dwell time for this material is ONLY 10 seconds.
Figure 7. Example of Under the Hood
1
2
Cavities Used to Fill Foam
1
2
Fill Area Evenly As Possible
© 2025 Toyota Motor Sales, USA
Holes Covered by Black Stickers
T-SB-0111-24
Rev1
December 4, 2024
Page 7 of 7
Abnormal Fluttering and/or Vibration Across Rear-Center Section of Hood
Repair Procedure (continued)
8. Ensure that all the insulator foam
is cured.
Figure 8. Example of Cured Insulator Foam
9. Clean all the excess foam from around the cavity openings and remove all protective coverings
from the engine bay, cowl, and windshield.
10. Re-install the hood insulator with NEW clips.
Refer to TIS, applicable model and model year Repair Manual.
2024 – 2025 Grand Highlander and Grand Highlander HV:
Vehicle Exterior – Door/Hatch – Hood – Reassembly
NOTE
Perform step 6 ONLY.
The insulator foam may interfere slightly with the insulator tabs.
Use a utility knife or flat head screwdriver to open a small slit for the insulator tabs.
11. Test-drive the vehicle to confirm the condition has been addressed.
© 2025 Toyota Motor Sales, USA
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TSB/Document ID: T-SB-0111-24 Rev1
Replacement Service Bulletin Number:
MFR Communication Date: 2025-07-15
MFR Internal Campaign ID/Software Version: T-SB-0111-24 Rev1
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: STRUCTURE:BODY
MFR Component System:
MFR Component Subsystem:
Previous TSB | Next TSB |
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