T-SB-0065-19

T-SB-0065-19
June 14, 2019
Abnormal Buzz/Groan Noise at 20 - 30 mph
Service
Category
Drivetrain
Section
Transfer/4wd/Awd
Market USA
Applicability
YEAR(S)
MODEL(S)
2019
RAV4
ADDITIONAL INFORMATION
Introduction
Some 2019 model year RAV4 vehicles may exhibit an abnormal buzz/groan noise at 20 – 30 mph
when accelerating from a stop and/or at 13 – 20 mph 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 AWD system. Follow the Repair Procedure in this bulletin to address
this condition.
NOTE
This Service Bulletin ONLY applies to 2019 model year RAV4 Limited and Adventure grade vehicles
with Torque Vectoring AWD System.
Warranty Information
OP CODE
DESCRIPTION
TIME
OFP
T1
T2
TC1902
R & R Transfer Case Electro-magnetic
Clutch Assembly
3.5
41406-42010
91
19
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.
© 2019 Toyota Motor Sales, USA
Page 1 of 14
T-SB-0065-19
June 14, 2019
Page 2 of 14
Abnormal Buzz/Groan Noise at 20 - 30 mph
Parts Information
PART NUMBER
PART NAME
QTY
41406-42010
Electro-magnetic Clutch Assy
1
N/A
90301-99240
O-ring*
1
90430-18008
90430-A0003
Transaxle Refill/Overflow Plug Gasket*
2
90341-18035
Drain Plug
1
12157-10010
Transfer Case Refill/Drain Plug Gasket*
2
90311-35056
Passenger Front Axle Seal*
1
90177-22001
Nut, Lock*
1
90119-10461
Bolt, W/Washer*
1
90521-75002
Ring, Hole Snap*
1
00289-ATFWS
Automatic Transmission Fluid WS
4
08885-02606
Transfer Case Gear Oil (LX85 LSD Type)
1
PREVIOUS
NEW
N/A
*Nonreusable part.
Required Tools & Equipment
REQUIRED EQUIPMENT
SUPPLIER
PART NUMBER
Techstream ADVi*
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.
 Software version 14.10.028 or later is required.
 Additional Techstream units may be ordered by calling Approved Dealer Equipment (ADE)
at 1-800-368-6787.
REQUIRED TOOLS & MATERIAL
PART NUMBER
QUANTITY
Body Grease W
08887-02007
1
MP (Multi-Purpose) Grease
–
As Needed
© 2019 Toyota Motor Sales, USA
T-SB-0065-19
June 14, 2019
Page 3 of 14
Abnormal Buzz/Groan Noise at 20 - 30 mph
Repair Procedure
Diagnosis
Confirm the vehicle exhibits an abnormal buzz/groan noise from the transfer case during one or
both of the following conditions.

Driving at 20 – 30 mph when accelerating from a stop during AWD system disconnect timing

Driving at 13 – 20 mph on deceleration during AWD system connect timing
NOTE
 Use chassis ears to confirm the noise is coming from the transfer case.
 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
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.
Does the vehicle exhibit an abnormal buzz/groan noise from the transfer case during one or both
conditions described above?

YES — Review the Component Overview subsection (pg. 4 – 5) and complete the
Repair Procedure in this Service Bulletin.

NO — This bulletin does NOT apply. Continue diagnosis using the applicable
Repair Manual.
© 2019 Toyota Motor Sales, USA
T-SB-0065-19
June 14, 2019
Page 4 of 14
Abnormal Buzz/Groan Noise at 20 - 30 mph
Repair Procedure (continued)
Component Overview (One of Two)
2
1
c
x2
7.5 N*m (76 kgf *cm 66 in*lbf )
x2
x2
x6
3*
8
49 N*m (500 kgf *cm, 36 f t*lbf)
39 N*m (398 kgf *cm, 29 f t*lbf)
7
3*
6
1.7 N*m (17 kgf *cm, 15 in*lbf )
3*
4*
3*
39 N*m (398 kgf *cm, 29 f t*lbf)
9
50 N*m (510 kgf *cm, 37 f t*lbf)
5
*Component to be replaced.
1
No. 2 Engine Under Cover Assembly
6
No. 1 Transmission Oil Filter Tube
2
Front Fender Apron Seal RH
7
Transfer Filler Plug
3
Gasket*
8
Refill Plug
4
Transfer Drain Plug
9
Torque Specification
5
Overflow Plug
© 2019 Toyota Motor Sales, USA
T-SB-0065-19
June 14, 2019
Page 5 of 14
Abnormal Buzz/Groan Noise at 20 - 30 mph
Repair Procedure (continued)
Component Overview (Two of Two)
47 N*m (479 kgf *cm 35 f t*lbf)
1*
2*
3*
4*
6*
5*
7*
74 N*m (755 kgf *cm, 55 f t*lbf)
x5
8
63.7 N*m (650 kgf *cm, 47 f t*lbf)
9
15
14
29 N*m (296 kgf *cm, 21 f t*lbf)
x3
8.5 N*m (87 kgf *cm, 75 in*lbf)
10
13
16*
32.4 N*m (330 kgf *cm, 24 f t*lbf)
294 N*m (2998 kgf *cm, 217 f t*lbf)
11*
12
x2
92 N*m (938 kgf *cm, 68 f t*lbf)
17
18
*Component to be replaced. (Component is part of the transfer case electro-magnetic clutch assembly.)
1
O-ring
10
Front Speed Sensor RH
2
Shim *
11
Front Axle Shaft Nut RH
(Do Not Apply Lubricant to Threaded Parts)
3
Arm ature Plate*
12
Front Low er No. 1 Suspension Arm Assembly RH
4
Thrust Roller Bearing*
13
Front Drive Shaft Assembly RH
5
Outer Plate*
14
Drive Shaft Bearing Bracket Hole Snap Ring
6
Cover*
15
Drive Shaft Bearing Bracket
7
Transfer Case Oil Seal (MP Grease)
16
Bolt
8
Front Stabilizer Link Assembly RH
17
Toyota Body Grease W (Application Area)
9
Front Flexible Hose
18
Torque Specification
NOTE
Tightening torque for major areas involving basic vehicle performance, such as moving, turning,
and stopping.
© 2019 Toyota Motor Sales, USA
T-SB-0065-19
June 14, 2019
Page 6 of 14
Abnormal Buzz/Groan Noise at 20 - 30 mph
Repair Procedure (continued)
Transfer Case Electro-magnetic Clutch Assembly Removal
1. Remove the front drive shaft assembly RH.
NOTE
Make sure to drain ALL automatic transaxle fluid and transfer oil BEFORE drive shaft removal to
prevent the two oils from mixing.
Refer to TIS, applicable model and model year Repair Manual:

2019 RAV4:
Drivetrain – Drive Shaft/Propeller Shaft – “Drive Shaft / Propeller Shaft: Front Drive Shaft
Assembly (for AWD): Removal”
NOTICE
Discard the old transfer case assembly drain plug after removal. Do NOT reuse the old
drain plug.
2. Remove the drive shaft bearing bracket.
3. Remove the transfer case electro-magnetic clutch.
A. Disconnect the connector.
Figure 1.
© 2019 Toyota Motor Sales, USA
T-SB-0065-19
June 14, 2019
Page 7 of 14
Abnormal Buzz/Groan Noise at 20 - 30 mph
Repair Procedure (continued)
Transfer Case Electro-magnetic Clutch Assembly Removal (continued)
B. Remove the five bolts and
electro-magnetic clutch
assembly cover.
Do NOT remove the three bolts
attaching the ring gear assembly
housing to the transfer case.
Figure 2.
2
1
2
2
NOTE
Gently remove the cover to prevent
the disconnect shaft from being
pulled out with the electro-magnetic
clutch assembly.
C. Remove the shim, armature plate,
thrust roller bearing, outer plate,
and cover.
1
Vehicle Upw ard
2
Bolt (Do Not Rem ove)
Figure 3.
5
D. Mark and store the five removed
components in a container for removed
components to avoid reinstalling them
in error.
1
c
2
3
4
1
Shim
2
Arm ature Plate
3
Thrust Roller Bearing
4
Outer Plate
5
Cover
© 2019 Toyota Motor Sales, USA
T-SB-0065-19
June 14, 2019
Page 8 of 14
Abnormal Buzz/Groan Noise at 20 - 30 mph
Repair Procedure (continued)
Transfer Case Electro-magnetic Clutch Assembly Removal (continued)
E. If the disconnect shaft is pulled out
together with the electro-magnetic
clutch cover, push it toward the vehicle
inner side (automatic transaxle side).
Figure 4.
NOTE
Make sure to push the disconnect shaft
back to its original position to ensure
proper installation of the NEW
electro-magnetic clutch.
1
c
2
1
Shaft
2
Push
Figure 5.
F. Remove the O-ring.
G. Destroy the removed O-ring and store it
in a container for removed components
to avoid reinstalling it in error.
© 2019 Toyota Motor Sales, USA
T-SB-0065-19
June 14, 2019
Page 9 of 14
Abnormal Buzz/Groan Noise at 20 - 30 mph
Repair Procedure (continued)
Transfer Case Electro-magnetic Clutch Assembly Installation
1. Install the NEW transfer case
electro-magnetic clutch.
A. Make sure the outer plate is securely
installed to the NEW transfer case
electro-magnetic clutch cover.
Figure 6.
1
c
NOTE
 Do NOT exchange ANY component
of the NEW transfer case
electro-magnetic clutch, in which shim
adjustment has been made, with any
other kit component.
 Do NOT disassemble the outer
plate from the cover of the NEW
electro-magnetic clutch.
2
1
Outer Plate (Do Not Rem ove)
2
Engraved Mark
NOTICE
Confirm that the outer plate is
attached in the correct position
to avoid damage to the outer
plate and/or misalignment
during installation.
B. Install the NEW O-ring.
Figure 7.
© 2019 Toyota Motor Sales, USA
T-SB-0065-19
June 14, 2019
Page 10 of 14
Abnormal Buzz/Groan Noise at 20 - 30 mph
Repair Procedure (continued)
Transfer Case Electro-magnetic Clutch Assembly Installation (continued)
NOTE
A NEW shim, armature plate, and thrust roller bearing MUST be installed to the transfer case
with the engraved mark surfaces facing the vehicle inner side (automatic transaxle side).
Figure 8.
1
2
3
4
5
6
6
6
1
Engraved Marks Facing Toward Vehicle
Inner Side (Automatic Transaxle Side)
4
Thrust Roller Bearing
2
Shim
5
Cover With Outer Plate
3
Arm ature Plate
6
Engraved Mark
C. Install the NEW shim to the transfer
case with its engraved mark surface
facing the vehicle inner side (automatic
transaxle side).
Figure 9.
NOTE
After proper installation, the engraved
mark should NOT be visible.
© 2019 Toyota Motor Sales, USA
T-SB-0065-19
June 14, 2019
Abnormal Buzz/Groan Noise at 20 - 30 mph
Repair Procedure (continued)
Transfer Case Electro-magnetic Clutch Assembly Installation (continued)
D. Install the NEW armature plate to the
transfer case with its engraved mark
surface facing the vehicle inner side
(automatic transaxle side).
Figure 10.
NOTE
After proper installation, the engraved
mark should NOT be visible.
E. Install the NEW thrust roller bearing to
the transfer case with its engraved
mark surface facing the vehicle inner
side (automatic transaxle side).
Figure 11.
NOTE
After proper installation, the engraved
mark should NOT be visible.
© 2019 Toyota Motor Sales, USA
Page 11 of 14
T-SB-0065-19
June 14, 2019
Abnormal Buzz/Groan Noise at 20 - 30 mph
Repair Procedure (continued)
Transfer Case Electro-magnetic Clutch Assembly Installation (continued)
F. Clean the surface where the NEW
transfer case electro-magnetic clutch
cover will be installed.
Figure 12.
G. Temporarily install the NEW transfer
case electro-magnetic clutch cover
together with the outer plate to the
transfer case with the five bolts.
1
c
NOTE
 Do NOT disassemble the outer plate
from the NEW transfer case
electro-magnetic clutch.
 Install the cover straight to prevent the
outer plate from moving out of place.
 Temporarily install the cover together
with the outer plate by tightening the
five bolts by hand. There will be
clearance of approximately 1 mm
between the transfer case and the
cover before fully tightening the bolts
to specified torque.
1
Vehicle Upw ard
Figure 13.
H. Tighten the four bolts.
Torque: 47 N*m (479 kgf*cm, 35 ft*lbf)
1
c
1
© 2019 Toyota Motor Sales, USA
Vehicle Upw ard
Page 12 of 14
T-SB-0065-19
June 14, 2019
Abnormal Buzz/Groan Noise at 20 - 30 mph
Repair Procedure (continued)
Transfer Case Electro-magnetic Clutch Assembly Installation (continued)
I.
Using a 14-mm socket wrench with
extensions, tighten the remaining
cover bolt.
Figure 14.
Torque: 47 N*m (479 kgf*cm, 35 ft*lbf)
1
c
1
J. Connect the connector.
Vehicle Upw ard
Figure 15.
2. Install the NEW transfer case oil seal RH.
3. Reinstall the drive shaft bearing bracket.
Torque: 63.7 N*m (650 kgf*cm, 47 ft*lbf)
© 2019 Toyota Motor Sales, USA
Page 13 of 14
T-SB-0065-19
June 14, 2019
Page 14 of 14
Abnormal Buzz/Groan Noise at 20 - 30 mph
Repair Procedure (continued)
Transfer Case Electro-magnetic Clutch Assembly Installation (continued)
4. Reinstall the front drive shaft assembly RH.
Refer to TIS, applicable model and model year Repair Manual:
 2019 RAV4:
Drivetrain – Drive Shaft/Propeller Shaft – “Drive Shaft / Propeller Shaft: Front Drive Shaft
Assembly (for AWD): Installation”
5. Add automatic transaxle fluid.
Refer to TIS, applicable model and model year Repair Manual:

2019 RAV4:
Drivetrain – Automatic Transmission/Transaxle – “UB80E (Automatic Transmission /
Transaxle): Automatic Transaxle Fluid: Adjustment”
6. Install the NEW transfer case assembly drain plug.
7. Add transfer oil.
Refer to TIS, applicable model and model year Repair Manual:

2019 RAV4:
General – Maintenance – “Maintenance: GF2A Transfer Oil: Replacement”
8. Reinstall the front under cover and front wheel RH.
9. Check and clear DTCs.
10. Inspect and adjust front wheel alignment.
Refer to TIS, applicable model and model year Repair Manual:
 2019 RAV4:
Suspension – Alignment/Handling Diagnosis – “Alignment / Handling Diagnosis: Front
Wheel Alignment: Adjustment”
11. Test-drive the vehicle and confirm the condition no longer exists.
© 2019 Toyota Motor Sales, USA