Toyota Kluger Common Problems

The Toyota Kluger is a seven-seat family SUV, sold in the US as the Highlander. Buyers here will meet four generations: the XU20 (2003 to 2007, V6 petrol with an automatic), the XU40 (2007 to 2014, 3.5-litre 2GR-FE V6 and five-speed auto), the XU50 (2014 to 2021) and the current XU70 (2021 on). The XU50 started with the 2GR-FE V6 and a six-speed auto, then gained the direct-injected 2GR-FKS V6 and an eight-speed auto in the 2017 facelift. The XU70 launched with that V6 and a 2.5-litre A25A-FXS hybrid with all-wheel drive, and the V6 gave way to a 2.4-litre T24A-FTS turbo four with an eight-speed auto from early 2023. The Kluger has a strong reliability record. Its known faults are mostly leaks, electrical niggles and recall items, not engine or gearbox failures.

Water pump leaks (3.5L 2GR-FE and 2GR-FKS V6, 2007 to 2022)

A leaking water pump is one of the mechanical jobs V6 Kluger owners report most often. Signs: a sweet coolant smell after a drive, a dried pink crust on the front of the engine near the pump, a coolant level that keeps dropping, or a growl from the pump bearing. Some XU40 owners report pumps weeping at higher kilometres, and some replace them as preventive work. A few XU50 owners report leaks much earlier, soon after the warranty ran out.

Do not ignore a weep: low coolant can overheat an aluminium V6. A replacement pump with fresh coolant usually costs roughly $600 to $1,200, depending on the workshop and whether the drive belt and thermostat are done at the same time.

Oil leaks from rubber oil hoses (3.5L 2GR-FE, 2007 to 2014)

The XU40 2GR-FE uses oil lines with rubber sections that can perish with age. In the US, Toyota ran a free campaign to replace the VVT-i oil supply hose on 2007 and 2008 Highlanders, the same car as our early XU40, because a pinhole could grow into a leak, cause engine noise and bring on the oil pressure light. Some Australian owners say they received a Toyota letter about seeps from the hoses between the engine and the oil cooler, with an all-metal line fitted when a leak was found.

A burst line can dump oil quickly, and some owners report oil reaching the hot exhaust. Fitting the revised metal parts typically costs $300 to $700 at an independent workshop. Ask whether it has been done, or ask a Toyota dealer if any support still applies to that VIN.

Hesitant or harsh shifts from the eight-speed auto (3.5L 2GR-FKS V6, 2017 to 2022)

The facelifted XU50 and the XU70 V6 use Toyota's eight-speed automatic. Some owners report hesitation from a standstill, revs flaring before an upshift, abrupt low-speed shifts and the gearbox hunting between gears in traffic. The same gearbox in the US Highlander received Toyota service bulletins for 2017 and 2018 cars that updated the software, and in some whining cases replaced the transmission. In the US, class actions have been filed alleging wider faults with this gearbox. They are allegations only, so check their current status.

Australian reports are fewer, and CarsGuide says the eight-speed has no known inherent weakness. Where a fault is found, a dealer software update is the usual first step. A replacement gearbox out of warranty would likely cost $7,000 to $12,000, so have any whine or slipping checked before you buy.

Power tailgate stops or will not open (XU50, 2014 to 2015)

A Toyota service bulletin covers early XU50s whose power tailgate may not work or may stop part way. The fix was new power tailgate actuators. Some XU40 owners also report failed tailgate switches. If the work was not done under warranty, new actuators can cost roughly $800 to $2,000 fitted, depending on parts and labour.

Peeling paint, especially on white cars (XU40 and early XU50, about 2012 to 2016)

Toyota had a run of factory paint problems around this period, and some Kluger owners report paint peeling in sheets from the roof, bonnet and sunroof surround. White cars seem worst affected, though other colours are mentioned too. A respray of the roof and bonnet can cost $1,500 to $4,000, so check the upper panels closely.

Flat 12V battery (XU70 hybrid, 2021 to 2024)

Some owners of the XU70 hybrid report the small 12V battery going flat, needing jump starts even on near-new cars, and a few say dealers found a failed cell and replaced the battery. Short trips, long periods parked and running accessories with the system off make it worse, and the car will not start without a healthy 12V battery. A replacement usually costs about $300 to $500.

Recalls and safety

The XU40 had recalls for the driver's power window master switch, which could wear, stick or overheat on cars built up to mid 2010. XU50 recalls covered a poorly welded fuel delivery pipe cap on some 2014 builds, the electric power steering circuit board on late 2014 builds, a brake booster vacuum pump on a small batch of late 2017 cars, and a low-pressure fuel pump on cars built from mid 2017 to late 2019 that could stop working and stall the engine. The XU70 has had front and second-row seat frames, a second-row seat recliner return spring on builds up to mid 2025, a lower front bumper cover that may detach, a reported side airbag wiring harness problem on some 2023 cars, and early hybrids whose stability control might not switch on at start-up. Have a Toyota dealer check the VIN for open recalls, and see our recalls page.

Buying a used Toyota Kluger? What to check

• Water pump: With the engine cold, look for pink crust or damp patches at the front of the V6 and check the coolant level. Ask whether the pump has been replaced on higher-kilometre cars.
• Oil leaks: On XU40 and early XU50 cars, look around the oil filter, oil cooler lines and under the engine for fresh oil. Ask if the metal oil lines have been fitted.
• Gearbox: Drive from cold and in stop-start traffic. Feel for hesitation, flaring revs, harsh shifts or a whine, and ask for records of any transmission software update.
• Power tailgate: Open and close it several times with the button and the key. It should run smoothly without stopping or reversing.
• Paint: Inspect the roof, bonnet and sunroof surround for lifting or peeling paint, especially on white cars.
• Hybrid health: On an XU70 hybrid, make sure it reaches Ready first time and ask for the dealer hybrid health check records, which also keep the extended hybrid battery warranty going.
• Recall work: Ask for proof the seat, bumper, fuel pump and other recall work has been done, or have a dealer confirm it from the VIN.
• Towing and use: A heavy tow bar, worn rear suspension or salt corrosion underneath points to boat launching. Look under AWD cars for off-road scrapes and ask about ex-fleet use.
• XU20 timing belt: The older XU20 V6 uses a timing belt. Ask for proof it has been changed on schedule, and be wary of an LPG conversion.

Before you pay, run a PPSR check for finance owing and write-off history, and work through our Toyota Kluger buying checklist.

The verdict

A well-serviced Kluger is a safe large SUV buy. The facelifted XU50 from 2017 to 2021 is the sweet spot: the stronger 2GR-FKS V6 and eight-speed auto, better safety gear and few serious faults, provided the gearbox drives smoothly and the water pump is dry. The XU70 hybrid is the pick for fuel use, as long as its recalls are done. An XU40 is good value if the oil lines and water pump have been sorted. Avoid any Kluger with patchy servicing, signs of heavy towing or an unexplained coolant leak.