NHTSA complaint #11765724

Owner complaint summary

Vehicle begin making grinding noises, and stalling during accelerating and also fuel smell. Took vehicle into Toyota Waldorf, MD dealership for diagnostic. At 58,000 miles, 2022 Toyota Highlander XLE stalls to accelerate due to front differentials failing, causing large chunks of metal on the drain plug indicating internal failure. Vehicle needs transmission and front differential replaced. I have 4 children, 3 of them still small, and driving with the fuel smell would impact them greatly as 1 of my children has asthma. It's also a hazard to be on the road with this vehicle as it can stall at any moment, causing a traffic incident. The problem has been reproduced by dealer, who is refusing to approve the fix under the 60,000 mile Power Train Warranty. There were no other warning signs, no check engine light came on, no issues prior to me hearing this grinding noise and stalling.