TSB005923

T-SB-0059-23
August 29, 2023
Hybrid Regenerative Brake Transition Feeling
Improvement
Service
Category
Brake
Section
Brake System
Market USA
Applicability
YEAR(S)
MODEL(S)
2020 - 2022
Highlander HV
ADDITIONAL INFORMATION
Introduction
Some drivers of 2020 – 2022 model year Highlander Hybrid vehicles may be sensitive to the
momentary transition from regenerative braking to hydraulic braking under certain driving
conditions, such as while driving downhill, or turning with light brake pedal application.
The brake actuator control module can be updated to improve brake feeling for this condition.
Follow the Repair Procedure in this bulletin to address this condition.
Warranty Information
OP CODE
DESCRIPTION
TIME
OFP
T1
T2
800159
Reprogram the Brake Actuator Assembly
Control Module
0.8
44050-#####*
38
99
*Warranty claim MUST be submitted with the correct 10-digit OFP. Choose the correct OFP for the vehicle being repaired
by searching for the parts in the Electronic Parts Catalog using the VIN filter.
APPLICABLE WARRANTY
 This repair is covered under the Toyota Basic Warranty. This warranty is in effect for
36 months or 36,000 miles, whichever occurs first, from the vehicle’s in-service date.
 Warranty application is limited to occurrence of the specified condition described in
this bulletin.
© 2023 Toyota Motor Sales, USA
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T-SB-0059-23
August 29, 2023
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Hybrid Regenerative Brake Transition Feeling Improvement
Parts Information
PART NUMBER
PART NAME
QTY
44050-#####
Actuator Assy, Brake
–
00451-00001-LBL
Authorized Modifications Label
1
NOTE
 The brake actuator assembly control module ECU should NOT be replaced as part of the
Repair Procedure.
 Authorized Modifications Labels may be ordered in packages of 25 from the Materials Distribution
Center (MDC) (portal.toyotamdc.com) under item No. 00451-00001-LBL.
Required Tools & Equipment
SPECIAL SERVICE TOOLS (SST)
PART NUMBER
QTY
Battery Diagnostic Tool*
DCA-8000P T
1
*Essential SST.
NOTE
Additional SSTs may be ordered by calling 1-800-933-8335.
REQUIRED EQUIPMENT
SUPPLIER
Techstream ADVI*
PART NUMBER
QTY
TSADVUNIT
Techstream 2.0
TS2UNIT
ADE
1
Techstream Lite
TSLITEPDLR01
Techstream Lite (Green Cable)
TSLP2DLR01
*Essential SST.
NOTE
 Only ONE of the Techstream units listed above is required.
 GTS+ software version 2023.03.001.02 or later is required.
 Additional Techstream units may be ordered by calling Approved Dealer Equipment (ADE)
at 1-800-368-6787.
 Use Techstream or an approved J2534 interface to perform flash reprogramming updates.
Visit techinfo.toyota.com for more information regarding J2534 reprogramming.
© 2023 Toyota Motor Sales, USA
T-SB-0059-23
August 29, 2023
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Hybrid Regenerative Brake Transition Feeling Improvement
Calibration Information
CALIBRATION ID
MODEL
Highlander HV
ENGINE
A25A-FXS
PREVIOUS
NEW
F15264872300
F15264872400
F15264872500
F152648J4000
F152648L5000
Repair Procedure
1. Confirm there are NO pre-existing conditions related to the brake system or hybrid systems.
A. Are there ANY brake or hybrid related DTCs?

YES — This bulletin does NOT apply. Continue diagnosis using the applicable
Repair Manual.

NO — Go to step 2.
B. Are the brake and hybrid systems operating to factory conditions?

YES — Continue to step 2.

NO — This bulletin does NOT apply. Continue diagnosis using the applicable
Repair Manual.
2. Does the driver sensation match the description of the momentary transition from
regenerative braking to hydraulic braking under certain driving conditions, such as while
driving downhill, or turning with light brake pedal application?

YES — Continue to step 3.

NO — This bulletin does NOT apply. Continue diagnosis using the applicable
Repair Manual.
© 2023 Toyota Motor Sales, USA
T-SB-0059-23
August 29, 2023
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Hybrid Regenerative Brake Transition Feeling Improvement
Repair Procedure (continued)
3. Use Techstream to confirm if the brake actuator assembly control module calibration has
been updated and check for the Authorized Modifications Label affixed to the vehicle in the
location shown below.
Is the calibration ID listed in Techstream and on the label the latest brake actuator assembly
ECU calibration?

YES — This bulletin does NOT apply. Continue diagnosis using the applicable
Repair Manual.

NO — Continue to step 4.
Figure 1. Location of Authorized Modifications Label on 2020 – 2022 Highlander Hybrid
TOYOTA MOTOR CORPORATION
AUTHORIZED MODIFICATIONS
THE FOLLOWING MODIFICATIONS HAVE BEEN MADE:
1
2
THESE MODIFICATIONS HAVE BEEN APPROVED
AS APPROPRIATE BY EPA AND CARB
3
DEALER CODE:
CHANGE AUTHORITY:
4
DATE:
5
1
Brake Actuator Assembly Part Number (e.g.,
44050-#####)
4
Date Completed
2
New Calibration ID (e.g., Main – F1526-48L5000)
5
This SB Number
3
Dealer Code
© 2023 Toyota Motor Sales, USA
T-SB-0059-23
August 29, 2023
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Hybrid Regenerative Brake Transition Feeling Improvement
Repair Procedure (continued)
4. Flash reprogram the brake actuator assembly control module.
NOTE
 The battery diagnostic tool MUST be used in Power Supply Mode to maintain battery voltage
at 13.5V while flash reprogramming the vehicle.
 For details on how to use the battery diagnostic station, refer to the DCA-8000 Instruction Manual
located at TIS – Diagnostics – Tools & Equipment – Battery Diagnostics.
Follow the procedures outlined in T-SB-0107-20, GTS+ ECU Flash Reprogramming With
Security Signature, and T-SB-0057-23, GTS+ ECU Flash Reprogramming Procedure, and
flash the brake actuator assembly control module with the NEW calibration file update.
5. Prepare and install the Authorized Modifications Label.
A. Using a permanent marker, enter the following information on the label:
 Brake Actuator Assembly part number [Refer to the Parts Information section for the
NEW PART NUMBER]

Calibration ID(s) [Refer to the Calibration Information section for the
NEW CALIBRATION ID]

Dealer Code
Repair Date
Change Authority [This bulletin number]


B. Install the Authorized Modifications Label onto the vehicle at the location shown in
Figure 1. The Authorized Modifications Label is available through the MDC,
P/N 00451-00001-LBL.
6. Clear ANY DTCs and test-drive the vehicle to confirm the condition is no longer present.
© 2023 Toyota Motor Sales, USA