NHTSA Complaint #11479720 — 2020 TOYOTA HIGHLANDER

While driving at approximately 45 MPH on a multi-lane parkway in Virginia, my wife and I heard a loud explosion which I immediately assumed might be a tire blowout. However, the steering system seemed normal as I slowed the car and began a move toward the road's shoulder. Within 10-15 seconds we began to hear the sound of "rushing air" above our heads. To determine why we heard that sound we slowly retracted the interior cabin fabric "head cover" to expose our sunroof; as soon as the "head cover" had retracted an inch or two it was clear that we had a large hole in the sunroof forward panel and that the tempered glass had shattered. We immediately closed the "head cover" and continued forward to our home which was a few miles away. As we drove, more and more "glass shards" were falling to the topside of our head cover. Fortunately, with our fabric head cover closed when the sunroof "failed" we were not showered by glass. However, had we had the sunroof exposed, I believe we would have had small glass pieces fall into the cabin area and on our heads. I have called my insurance company (USAA) and they have processed my claim sending me to SAFELITE which in turn has forwarded my repair work to SUNROOF EXPRESS. I called my Toyota Dealership which told me the sunroof is no longer under warranty. I can only speculate that the failure was caused either by a "micro-defect" in the sunroof which over time and temperature changes (summer heat, interior cool from A/C, winter freeze, etc) caused a sudden failure; or, it's possible a rock/pebble kicked up by a vehicle somewhere in front of us had a trajectory high enough (higher than our front windshield) and then impacted the sunroof at a sufficient angle to cause its failure. Following this incident with my car, I went on-line and discovered that I'm not alone. Apparently many other motorists have experienced what they describe as "explosive" sunroof failures...and some have been showered in glass. Not good!