Headlights problems of the 2004 Toyota Highlander

I noticed that my original equipment/manufacturer passenger-side low-beam headlight lens had a burnt spot on the inside of the lens (clearly melted lens material). I checked the headlight bulb, which is a factory-installed kaito model hb3 low-beam bulb. The bulb was discolored black and smoky looking with an obvious bulge of melted glass in one side of the bulb. The low-beam headlights still work, but the bulb seemingly has overheated, melting both the bulb glass and the inside of the lens assembly.

The contact owns a 2004 Toyota Highlander. The contact noticed condensation and moisture in both the driver and passenger side headlight lenses. In addition, the driver's side headlight lenses had melted and exhibited a bubble. The manufacturer was notified of the problem. The approximate failure mileage was 100,000. The VIN was unavailable.

Late last year we noticed that the dayrunning portion of the headlamp cover had melted on the inside, next to the tip of the bulbs on each side. There is no way to turn the dayrunning feature on or off, it is always on. Not only does this wear down the battery, which we've already replaced in one year, but the headlight cover cannot handle the heat generated from constantly being "on". We would like this issue resolved and a discount given on a new set, since it isn't our fault, as it couldn't be turned off. Headlights are expensive, and at night it is a safety issue, since our visibility is drastically reduced- where we live, there are deer and winding hilly roads. If Toyota won't do anything, we will be forced to do this expensive repair ourselves, but will be very, very disappointed. Toyota should stand behind their product, this is a design flaw and a huge safety issue.

Recently discovered two white melted bumps in the exact center of the headlamp casing where the daytime running lamp beams pass through the plastic. Have only had the vehicle since July 2010 and the incident occured during a 19 hour drive, most of which took place during daylight hours. Headlights were not turned on until sunset. Concerned that factory lights are hot enough to melt the plastic that is factory installed. Obvious defect, could cause fire. Impaired vision at night also a result as plastic is now permanently damaged. Also concerned that issue could worsen and hole could appear, causing rain and elements to come in direct contact with lighting system. Another obvious danger. Disengaging daytime lights is not an option, no control over overheating other to turn on headlights 100% of time. Also concerned with this solution, as defect could potentially be similar in these as well. Attempted to have dealer look at problem, however warrantly period has expired. After researching online, found several similar instances on models ranging from 2004-2007. Feel strongly that issue should be investigated as passenger saftey is at risk.

The contact owns a 2004 Toyota Highlander. The plastic on the headlights have peeled, subsequently causing the lights to appear very dim. The vehicle was taken to the dealer and the technician concluded that buffing would remedy the failure. The failure mileage was 40000. The current mileage was 51400, updated 10/19/09 updated 10/19/09.

The contact owns a 2004 Toyota Highlander. The contact stated that the headlights would intermittently overheat and melt without warning. The dealer advised the failure was due to the bulb becoming extremely hot and melting the head light lens. The vehicle was not repaired. The failure mileage was 44,000 and the current mileage was 51,000.

I was leaving my home going to work today and noticed that my wife's Toyota 2004 Highlander headlight lenses had started to melt where the day time running lamps are.

I have a 2004 Toyota highland and believe there is a design defect or manufacturing flaw with regard to the lens covers to the headlights and fog light covers. Both have significant melting from the light bulbs. I am concerned that the vehicle will catch on fire. All products involved are original Toyota parts. The lens covers each have a large (bigger than a quarter) circular spot where the melting took place from the inside out and there is a bubble on each. The same has happened with the fog lights and they are now cracked from the heat. I have contacted Toyota and they will not fix, replace, repair the lens covers and say that there is no recall. I would imagine that anything melting on a vehicle has the potential to catch fire. This has been progressively getting worse over several years so the incident date is not exact. It is evident that eventually there will be holes in these covers from the heat/melting as the daylights run constantly and cannot be turned off.

The new model year 04 Toyota Highlander SUV and sienna vans have poorly designed and or misadjusted daytime running lights, causing blinding glare to on coming drivers, drivers in front of these vehicles and pedestrians walking at night. These excessively glaring lights distract and cause eye pain to other drivers and temporary blindness. This is a serious safety problem that needs to be addressed especially for pedestrians walking against traffic at night.