T-SB-0065-19_Rev

T-SB-0065-19
Rev1
June 14, 2019
Abnormal Buzz/Groan Noise at 20 – 30 mph From Front
Transfer Case
Service
Category
Drivetrain
Section
Transfer/4wd/Awd
Market USA
Applicability
YEAR(S)
MODEL(S)
2019
RAV4
ADDITIONAL INFORMATION
REVISION NOTICE
November 20, 2019 Rev1:
 The Introduction, Production Change Information, and Repair Procedure sections have been
updated.
Any previous printed versions of this bulletin should be discarded.
Introduction
Some 2019 model year RAV4 Adventure and Limited grade AWD vehicles may exhibit an
abnormal buzz/groan noise from the front transfer case 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 the
AWD system. Follow the Repair Procedure in this bulletin to address this condition.
NOTE
This Service Bulletin ONLY applies to 2019 model year RAV4 Adventure and Limited grade vehicles
with torque vectoring AWD system.
© 2019 Toyota Motor Sales, USA
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T-SB-0065-19
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Abnormal Buzz/Groan Noise at 20 – 30 mph From Front Transfer Case
Production Change Information
Production change information for hardware changes to front transfer case assembly ONLY.
MODEL
RAV4
PLANT
DRIVETRAIN
PRODUCTION CHANGE EFFECTIVE VIN
TMMC North
2T3J1RFV#4KC053454
TMMC West
2T3N1RFV#1KW080109
Takaoka
AWD
JTMD13FV#1KJ022931
Shokki #1
JTMD13FV#30D041220
Shokki #2
JTMD13FV#9LD522366
Warranty Information
OP CODE
DESCRIPTION
TIME
OFP
T1
T2
TC1902
R & R Front 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
T-SB-0065-19
Rev1
June 14, 2019
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Abnormal Buzz/Groan Noise at 20 – 30 mph From Front Transfer Case
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
Front 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
Front 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 14.20.019 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
Rev1
June 14, 2019
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Abnormal Buzz/Groan Noise at 20 – 30 mph From Front Transfer Case
Repair Procedure
Diagnosis
Confirm the vehicle exhibits an abnormal buzz/groan noise from the front 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 front 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 front transfer case during one or
both conditions described above?

YES — Review the Component Overview subsection (pgs. 5 and 6) 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
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Abnormal Buzz/Groan Noise at 20 – 30 mph From Front Transfer Case
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 ft*lbf)
39 N*m (398 kgf*cm, 29 ft*lbf)
7
3*
6
1.7 N*m (17 kgf*cm, 15 in*lbf)
3*
4*
3*
39 N*m (398 kgf*cm, 29 ft*lbf)
9
50 N*m (510 kgf*cm, 37 ft*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
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Abnormal Buzz/Groan Noise at 20 – 30 mph From Front Transfer Case
Repair Procedure (continued)
Component Overview (Two of Two)
47 N*m (479 kgf*cm, 35 ft*lbf)
1*
2*
3*
4*
6*
5*
7*
74 N*m (755 kgf*cm, 55 ft*lbf)
x5
8
63.7 N*m (650 kgf*cm, 47 ft*lbf)
9
15
14
29 N*m (296 kgf*cm, 21 ft*lbf)
x3
8.5 N*m (87 kgf*cm, 75 in*lbf)
10
13
16*
32.4 N*m (330 kgf*cm, 24 ft*lbf)
294 N*m (2998 kgf*cm, 217 ft*lbf)
11*
12
x2
17
92 N*m (938 kgf*cm, 68 ft*lbf)
18
*Component to be replaced. (Component is part of the front 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
Armature Plate*
12
Front Lower 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
Front 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
Rev1
June 14, 2019
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Abnormal Buzz/Groan Noise at 20 – 30 mph From Front Transfer Case
Repair Procedure (continued)
Front 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 front 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
Rev1
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Abnormal Buzz/Groan Noise at 20 – 30 mph From Front Transfer Case
Repair Procedure (continued)
Front Transfer Case Electro-magnetic Clutch Assembly Removal (continued)
B. Remove the five bolts and
electro-magnetic clutch
assembly cover.
Figure 2.
2
Do NOT remove the three bolts
attaching the ring gear assembly
housing to the transfer case.
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 Upward
2
Bolt (Do NOT Remove)
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
Armature Plate
3
Thrust Roller Bearing
4
Outer Plate
5
Cover
© 2019 Toyota Motor Sales, USA
T-SB-0065-19
Rev1
June 14, 2019
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Abnormal Buzz/Groan Noise at 20 – 30 mph From Front Transfer Case
Repair Procedure (continued)
Front 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
Rev1
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Abnormal Buzz/Groan Noise at 20 – 30 mph From Front Transfer Case
Repair Procedure (continued)
Front Transfer Case Electro-magnetic Clutch Assembly Installation
1. Install the NEW front transfer case electro-magnetic clutch.
A. Make sure the outer plate is securely installed to the NEW front transfer case electromagnetic clutch cover.
NOTE
 Do NOT exchange ANY component of the NEW front 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.
Key Points:
 Engraved markings MUST be visible.
When installed, engraved markings (numbers) will face inward toward the front
transfer case/transaxle.
 Outer plate is clocked correctly out of the box as NEW part (it is important to NOT
remove the outer plate from the EMC cover).
The reason for NOT removing the outer plate is because it can be easily
bent/damaged (no reason to handle outside of the cover).
Figure 6.
1
Engraved Markings Clocked Near 180° From This Notch
2
Engraved Markings: Correct Position Right Out of the Box as New Part
3
Engraved Markings
© 2019 Toyota Motor Sales, USA
T-SB-0065-19
Rev1
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Abnormal Buzz/Groan Noise at 20 – 30 mph From Front Transfer Case
Repair Procedure (continued)
Front Transfer Case Electro-magnetic Clutch Assembly Installation (continued)
Figure 7.
B. Install the NEW O-ring.
NOTE
A NEW shim, armature plate, and thrust roller bearing MUST be installed to the front transfer
case with the engraved mark surfaces facing the vehicle inner side (automatic transaxle side). If
engraved markings are visible AFTER installation of either shim, armature, and/or needle
bearing, the customer may experience the same buzz/groan noise concern AFTER repair.
Ensure engraved markings are NOT visible when installing these three components.
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
Armature Plate
6
Engraved Mark
© 2019 Toyota Motor Sales, USA
T-SB-0065-19
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June 14, 2019
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Abnormal Buzz/Groan Noise at 20 – 30 mph From Front Transfer Case
Repair Procedure (continued)
Front Transfer Case Electro-magnetic Clutch Assembly Installation (continued)
C. Install the NEW shim to the front
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.
D. Install the NEW armature plate to the
front 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.
© 2019 Toyota Motor Sales, USA
T-SB-0065-19
Rev1
June 14, 2019
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Abnormal Buzz/Groan Noise at 20 – 30 mph From Front Transfer Case
Repair Procedure (continued)
Front Transfer Case Electro-magnetic Clutch Assembly Installation (continued)
E. Install the NEW thrust roller bearing to
the front 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.
Figure 12. No Good vs OK Condition
1
No Good Condition
2
OK Condition
© 2019 Toyota Motor Sales, USA
T-SB-0065-19
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June 14, 2019
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Abnormal Buzz/Groan Noise at 20 – 30 mph From Front Transfer Case
Repair Procedure (continued)
Front Transfer Case Electro-magnetic Clutch Assembly Installation (continued)
F. Clean the surface where the NEW front
transfer case electro-magnetic clutch
cover will be installed.
Figure 13.
G. Temporarily install the NEW front
transfer case electro-magnetic clutch
cover together with the outer plate to
the front transfer case with the
five bolts.
1
c
NOTE
 Do NOT disassemble the outer plate
from the front NEW front 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 front transfer case and the
cover BEFORE fully tightening the
bolts to specified torque.
H. Tighten the four bolts.
Torque: 47 N*m (479 kgf*cm, 35 ft*lbf)
1
Vehicle Upward
Figure 14.
1
c
1
© 2019 Toyota Motor Sales, USA
Vehicle Upward
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Abnormal Buzz/Groan Noise at 20 – 30 mph From Front Transfer Case
Repair Procedure (continued)
Front Transfer Case Electro-magnetic Clutch Assembly Installation (continued)
I.
Using a 14-mm socket wrench with
extensions, tighten the remaining
cover bolt.
Torque: 47 N*m (479 kgf*cm, 35 ft*lbf)
Figure 15.
1
c
1
J. Connect the connector.
Vehicle Upward
Figure 16.
2. Install the NEW front 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
T-SB-0065-19
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June 14, 2019
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Abnormal Buzz/Groan Noise at 20 – 30 mph From Front Transfer Case
Repair Procedure (continued)
Front 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 front 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