T-SB-0067-20

T-SB-0067-20
July 8, 2020
Abnormal Noise From Rear Differential During
Connect/Disconnect Operation
Service
Category
Drivetrain
Section
Axle/Differential
Market USA
Applicability
YEAR(S)
MODEL(S)
ADDITIONAL INFORMATION
2019 - 2020
RAV4
WMI(s): 2T3, JTM
VDS(s): J1RFV, N1RFV
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
OP CODE
DESCRIPTION
TIME
OFP
T1
T2
TC1906
R & R Differential Carrier Assembly
for Torque Vectoring Differential
5.0
41110-42050
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.
© 2020 Toyota Motor Sales, USA
Page 1 of 6
T-SB-0067-20
July 8, 2020
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Abnormal Noise From Rear Differential During Connect/Disconnect Operation
Production Change Information
This bulletin applies to vehicles with a differential produced BEFORE the effective serial number
shown below.
MODEL
PLANT
DRIVETRAIN
PRODUCTION CHANGE EFFECTIVE SERIAL NUMBER
AWD
20E15F1013
TMMC - C
TMMC - W
RAV4
Takaoka
Shokki #1
Shokki #2
1. Locate the differential serial number, as shown in the figure below.
Figure 1. Real Differential Front View
1
2
1
Propeller Shaft
2
Rear Differential Serial Number
© 2020 Toyota Motor Sales, USA
T-SB-0067-20
July 8, 2020
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Abnormal Noise From Rear Differential During Connect/Disconnect Operation
Production Change Information (continued)
2. Use the figure below as a guide to determine the production date from the serial number.
Figure 2. Rear Differential Serial Number Breakdown
Example:18Y23F1087  Produced November 23, 2018
Production Month






Year (YY) / Month (M) / Day (DD)
A: Jan
B: Feb
C: Mar
D: Apr
E: May
F: Jun






G: Jul
H: Aug
I: Sep
X: Oct
Y: Nov
Z: Dec
Parts Information
PART NUMBER
PREVIOUS
PART NAME
QTY
Carrier Assy, Differential
1
NEW
41110-42050
41110-42051
41110-42053
41110-42052
90119-12453
90119-12455
2
Bolt, W/Washer*
90119-14186
2
1
90105-14210
Bolt, Flange*
3
90179-A0005
Nut*
2
08885-02606
LX GL-5 75W-85 Gear Oil (LX85 LSD Type)
1
12159-10010
Gasket, Drain Plug*
1
*Nonreusable parts.
© 2020 Toyota Motor Sales, USA
T-SB-0067-20
July 8, 2020
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Abnormal Noise From Rear Differential During Connect/Disconnect Operation
Required Tools & Equipment
REQUIRED EQUIPMENT
SUPPLIER
PART NUMBER
Techstream ADVi*
TSADVUNIT
Techstream 2.0
TS2UNIT
QTY
1
Techstream Lite
ADE
TSLITEPDLR01
Techstream Lite (Green Cable)
TSLP2DLR01
ChassisEAR™ (or Equivalent)
JSP06608
1
*Essential SST.
NOTE




Only ONE of the Techstream units listed above is required.
Software version 15.00.028 or later is required.
A mechanic’s stethoscope or similar tool may be used in place of ChassisEAR™.
ChassisEAR™ and Additional Techstream units may be ordered by calling Approved Dealer Equipment
(ADE) at 1-800-368-6787.
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.

© 2020 Toyota Motor Sales, USA
T-SB-0067-20
July 8, 2020
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Abnormal Noise From Rear Differential During Connect/Disconnect Operation
Repair Procedure (continued)
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.
Refer to TIS, applicable model and model year Repair Manual:

2019 RAV4:
Drivetrain – Axle/Differential – “Axle and Differential: Rear Differential Carrier Assembly
(for Torque Vectoring Differential): Removal”

2020 RAV4:
Drivetrain – Axle/Differential – “Axle and Differential: Rear Differential Carrier Assembly
(for Torque Vectoring Differential): Removal”
NOTE
Reuse the side couplers/harness and brackets from OE unit removed.
© 2020 Toyota Motor Sales, USA
T-SB-0067-20
July 8, 2020
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Abnormal Noise From Rear Differential During Connect/Disconnect Operation
Repair Procedure (continued)
4. For information regarding how to disassemble and reassemble the rear differential carrier
assembly (torque vectoring differential) refer to TIS, applicable model and model year
Repair Manual:

2019 – 2020 RAV4:
Drivetrain – Axle/Differential – “Axle and Differential: Rear Differential Carrier Assembly
(for Torque Vectoring Differential): Disassembly” ONLY steps 1 – 4 and 12 – 13

2019 – 2020 RAV4:
Drivetrain – Axle/Differential – “Axle and Differential: Rear Differential Carrier Assembly
(for Torque Vectoring Differential): Reassembly” ONLY steps 17 – 18 and 25 – 28

2019 – 2020 RAV4:
Drivetrain – Axle/Differential – “Axle and Differential: Rear Differential Carrier Assembly
(for Torque Vectoring Differential): Installation”
5. Using Techstream, check and clear ANY DTCs.
6. Test-drive the vehicle and confirm the condition no longer exists.
© 2020 Toyota Motor Sales, USA