2019-2020 Toyota RAV4 Abnormal Noise From Rear Differential During Connect/Disconnect Operation T-SB-0067-20

MG

Moderator
This Bulletin is Obsolete and has been Superseded to T-SB-0022-22 Revision 1. Please see here...

Please see T-SB-0067-20

Applicability:
2019-2020 RAV4
WMI(s): 2T3, JTM
VDS(s): J1RFV, N1RFV (Please see this Post to determine WMI and VDS)

Introduction:
Some 2019 – 2020 model year RAV4 Adventure and Limited grade AWD vehicles may exhibit an abnormal noise from the rear differential assembly when accelerating from a stop and/or on deceleration after driving the vehicle for 15 – 20 minutes or more. This condition occurs with Normal drive mode selected during disconnect/connect timing of the AWD system. Follow the Repair Procedure in this bulletin to address this condition

NOTE:
This Service Bulletin ONLY applies to 2019 – 2020 model year RAV4 Adventure and Limited grade vehicles with torque vectoring AWD system.

Warranty Information:
R & R Differential Carrier Assembly for Torque Vectoring Differentia

APPLICABLE WARRANTY:
This repair is covered under the Toyota Powertrain Warranty. This warranty is in effect for 60 months or 60,000 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.

Production Change Information:
1. Locate the differential serial number, as shown on the Rear Diffrential.
This bulletin applies to vehicles with a differential produced BEFORE the effective serial number shown below.
PRODUCTION CHANGE EFFECTIVE SERIAL NUMBER: 20E15F1013

2. Use the figure below as a guide to determine the production date from the serial number.
Example:18Y23F1087 = Produced November 23, 2018
Year (YY) / Month (M) / Day (DD)
Production Month A: Jan B: Feb C: Mar D: Apr E: May F: Jun G: Jul H: Aug I: Sep X: Oct Y: Nov Z: Dec

Repair Procedure:
1. Confirm the vehicle exhibits one of the following abnormal noises from the rear differential assembly when accelerating from a stop during AWD system disconnect timing or upon deceleration during AWD system connect timing:
* Buzz/Groan
* Single, Double, or Triple Clunk
* Ratchet/Grinding
* Bang/Thump

NOTE:
Use ChassisEAR™ to confirm the noise is coming from the rear differential assembly.
Monitor the 4WD ECU Data List “Front and rear axle coupling position sensor status” to confirm the noise is occurring at AWD system disconnect and/or connect timing.

HINT:
On 2019 model year RAV4 vehicles, while driving above 20 mph, the system can be manually switched back and forth from disconnect to connect by switching drive mode from Normal to Sport.
On 2020 model year RAV4 vehicles, while driving above 50 mph, the system can be manually switched back and forth from disconnect to connect by switching drive mode from Normal to Sport.

A. Does the vehicle exhibit an abnormal noise during one or more of the conditions described above?
YES — Continue to sub step B.
NO — This bulletin does NOT apply. Continue diagnosis using the applicable Repair Manual.

B. Does the abnormal noise come from the rear differential assembly?
YES — Continue to step 2.
NO — This bulletin does NOT apply. Continue diagnosis using the applicable Repair Manual

2. Confirm the rear differential assembly production date is BEFORE May 15th, 2020. Does the differential serial number show a production date BEFORE the effective serial number in the Production Change Information section? See the Production Change Information section for details.
YES — Continue to step 3.
NO — This bulletin does NOT apply. Continue diagnosis using the applicable Repair Manual.

3. Replace the rear differential carrier assembly.

4. Using Techstream, check and clear ANY DTCs.

5. Test-drive the vehicle and confirm the condition no longer
exists.
 
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