NHTSA Complaint #10413917 — 2004 TOYOTA HIGHLANDER

INTERMITTENT LOSS OF A/C AND/OR HEAT AND FINALLY TOTAL LOSS OF A/C ON MY 2004 TOYOTA HIGHLANDER. INITIAL FIX WAS TO TIGHTEN THE NUT ON THE TEMPERATURE CONTROL. I FOUND THAT THIS PROBLEM WAS INHERENT AFTER GOING TO THE WEB AND LEARNING OF THE MANY PROBLEMS WITH THE ASSEMBLY AND THE QUICK FIX. ESSENTIALLY THE A/C STOPPED WORKING ENTIRELY. I BROUGHT IT TO MY PRIVATE MECHANIC AND HE FOUND THAT THE CABLE FROM THE TEMPERATURE CONTROL TO THE MOTHER BOARD WAS BROKEN. I INQUIRED HOW THIS COULD HAPPEN AND WAS ADVISED THAT WHEN THE NUT ON THE TEMPERATURE CONTROL CAME LOOSE, THE WHOLE UNIT WAS TURNING WHEN I WAS ADJUSTING THE TEMPERATURE, WHICH CAUSED THE CABLE TO BREAK. THE LACK OF A LOCK WASHER OVER THE FLAT WASHER WAS THE CULPRIT THAT ALLOWED THE NUT TO COME LOOSE. BECAUSE THE CABLE FROM THE MOTHERBOARD TO THE TEMPERATURE CONTROL IS HARD WIRED, THE ENTIRE ASSEMBLY HAD TO BE REPLACED AT A COST OF APPROXITMATELY $950.00. NOTE: I HAVE THE ENTIRE FAULTY ASSEMBLY AT HOME, IN THE EVENT YOU REQUIRE TO SEE IT. *KB