T-SB-0019-20 Rev

T-SB-0019-20
Rev2
March 3, 2020
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 - 2020
RAV4
ADDITIONAL INFORMATION
REVISION NOTICE
October 21, 2020 Rev2:
 Applicability has been updated to include 2020 model year RAV4 vehicles.
 The Parts Information, Production Change Information, and Warranty Information sections have
been updated.
July 29, 2020 Rev1:
 The entire bulletin has been updated.
Any previous printed versions of this bulletin should be discarded.
SUPERSESSION NOTICE
The information contained in this bulletin supersedes Service Bulletin No. T-SB-0065-19.
 Production Change Information section has been updated.
Service Bulletin No. T-SB-0065-19 is obsolete and any printed versions should be discarded.
Introduction
Some 2019 – 2020 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 20 – 13 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 – 2020 model year RAV4 Adventure and Limited grade
vehicles with torque vectoring AWD system.
© 2020 Toyota Motor Sales, USA
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T-SB-0019-20
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Abnormal Buzz/Groan Noise at 20 - 30 mph From Front Transfer Case
Production Change Information
This bulletin applies to vehicles produced BEFORE the Production Change Effective VINs
shown below.
MODEL
PLANT
DRIVETRAIN
PRODUCTION CHANGE EFFECTIVE VIN
2T3N1RFV#KC053454
TMMC - C
2T3J1RFV#KC053454
2T3N1RFV#LW087451
TMMC - W
RAV4
AWD
2T3J1RFV#LW087451
Takaoka
JTMN1RFV#KJ023026
Shokki #1
JTMN1RFV#KD041318
Shokki #2
JTMN1RFV#KD522367
Warranty Information
OP CODE
DESCRIPTION
TIME
TC1912
R & R Front Transfer Case
Electro-magnetic Clutch Assembly
3.7
Reprogram 4WD ECU
0.5
Combo A
OFP
T1
T2
41406-42010*
91
19
*Choose the correct OFP for the vehicle being repaired by searching the parts in EPC using the EPC VIN filter.
Warranty claims must be submitted with the correct OFP with 10 digits.
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
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Abnormal Buzz/Groan Noise at 20 - 30 mph From Front Transfer Case
Parts Information
PART NUMBER
PART NAME
QTY
Repair Kit, Transfer
1
00289-ATFWS
Automatic Transmission Fluid WS
4
08885-02606
Front Transfer Case Gear Oil (LX85 LSD Type)
1
00451-00001-LBL
Authorized Modifications Labels
1
Computer Assy, 4WD
–
PREVIOUS
NEW
–
04000-28142
89630-42130
89630-42140
89630-42160
NOTICE
The 4WD ECU should NOT be replaced as part of the Repair Procedure.
NOTE
Authorized Modifications Labels may be ordered in packages of 25 from the Materials
Distribution Center (MDC) through Dealer Daily – Parts – Dealer Support Materials Orders.
© 2020 Toyota Motor Sales, USA
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Abnormal Buzz/Groan Noise at 20 - 30 mph From Front Transfer Case
Required Tools & Equipment
REQUIRED TOOLS & MATERIAL
PART NUMBER
QUANTITY
Body Grease W
08887-02007
1
MP (Multi-purpose) Grease
–
As Needed
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 15.20.016 or later is required.
 ChassisEAR™ and additional Techstream units may be ordered by calling Approved Dealer Equipment
(ADE) at 1-800-368-6787.
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.
Calibration Information
GRADE
ECU
Adventure
Limited
4WD ECU
CALIBRATION ID
PREVIOUS
NEW
F15364209200
F15364210000
F15364212000
F15364212100
© 2020 Toyota Motor Sales, USA
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Abnormal Buzz/Groan Noise at 20 - 30 mph From Front Transfer Case
Repair Procedure
1. 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 20 – 13 mph on deceleration during AWD system connect timing.
Refer to the buzz/groan noise example video link:
Buzz/Groan Noise Example Video
NOTE
 Use ChassisEAR™ 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 Figure 1 and Figure 2 (pgs. 6 and 7) and complete the rest of the
Repair Procedure in this bulletin.

NO — This bulletin does NOT apply. Continue diagnosis using the applicable
Repair Manual.
© 2020 Toyota Motor Sales, USA
T-SB-0019-20
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Abnormal Buzz/Groan Noise at 20 - 30 mph From Front Transfer Case
Repair Procedure (continued)
Figure 1. Component Overview 1 of 2
2
1
c
x2
Torque: 7.5 N*m (76 kgf*cm, 66 in*lbf)
x2
x2
x6
3*
8
Torque: 49 N*m (500 kgf*cm, 36 ft*lbf)
Torque: 39 N*m (398 kgf*cm, 29 ft*lbf)
7
3*
6
Torque: 1.7 N*m (17 kgf*cm, 15 in*lbf)
3*
4*
3*
Torque: 50 N*m (510 kgf*cm, 37 ft*lbf)
5
Torque: 39 N*m (398 kgf*cm, 29 ft*lbf)
1
No. 2 Engine Under Cover Assembly
5
Overflow Plug
2
Front Fender Apron Seal RH
6
No. 1 Transmission Oil Filter Tube
3
Gasket*
7
Transfer Filler Plug
4
Transfer Drain Plug
8
Refill Plug
*Component to be replaced.
© 2020 Toyota Motor Sales, USA
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Abnormal Buzz/Groan Noise at 20 - 30 mph From Front Transfer Case
Repair Procedure (continued)
Figure 2. Component Overview 2 of 2
Torque: 47 N*m (479 kgf*cm, 35 ft*lbf)
1* 47 N*m (479 kgf*cm, 35 ft*lbf)
2*
3*
4*
6*
47 N*m (479 kgf*cm,
35 ft*lbf)
5*
Torque: 74 N*m (755 kgf*cm, 55 ft*lbf)
8
Torque: 63.7 N*m (650 kgf*cm, 47 ft*lbf)
15
7*
47 N*m (479 kgf*cm, 35x5
ft*lbf)
9
14
Torque: 29 N*m (296 kgf*cm, 21 ft*lbf)
x3
Torque: 8.5 N*m (87 kgf*cm, 75 in*lbf)
10
13
16*
Torque: 32.4 N*m (330 kgf*cm, 24 ft*lbf)
Torque: 294 N*m (2998 kgf*cm, 217 ft*lbf)
11*
12
x2
17
Torque: 92 N*m (938 kgf*cm, 68 ft*lbf)
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
*Component to be replaced. (Component is part of the front transfer case electro-magnetic clutch assembly.)
NOTE
Tighten torque for major areas involving basic vehicle performance, such as moving, turning,
and stopping.
© 2020 Toyota Motor Sales, USA
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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 – 2020 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 3.
© 2020 Toyota Motor Sales, USA
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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 4.
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 5.
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
© 2020 Toyota Motor Sales, USA
T-SB-0019-20
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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 6.
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 7.
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.
© 2020 Toyota Motor Sales, USA
T-SB-0019-20
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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
electro-magnetic 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 (there is no reason to handle outside of the cover).
Figure 8.
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
© 2020 Toyota Motor Sales, USA
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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 9.
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 the repair.
Ensure the engraved markings are NOT visible when installing these three components.
Figure 10.
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
© 2020 Toyota Motor Sales, USA
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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 11.
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 12.
NOTE
AFTER proper installation, the engraved
mark should NOT be visible.
© 2020 Toyota Motor Sales, USA
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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 13.
NOTE
AFTER proper installation, the engraved
mark should NOT be visible.
Figure 14. No Good vs OK Condition
1
2
z
1
No Good Condition
2
OK Condition
© 2020 Toyota Motor Sales, USA
z
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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 15.
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 16.
1
c
1
© 2020 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 17.
1
c
1
J. Connect the connector.
Vehicle Upward
Figure 18.
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)
© 2020 Toyota Motor Sales, USA
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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 – 2020 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 – 2020 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 – 2020 RAV4:
General – Maintenance – “Maintenance: GF2A Transfer Oil: Replacement”
8. Reinstall the front under cover and front wheel RH.
© 2020 Toyota Motor Sales, USA
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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)
9. Use Techstream to confirm if the 4WD ECU 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 4WD ECU calibration?

YES — Go to step 12.

NO — Continue to step 10.
Figure 19. Location of Authorized Modifications Label on 2019 – 2020 RAV4
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
Replacement ECM (PCM) Part Number
(e.g., 89630-42160)
4
Date Completed
2
New Calibration ID (e.g., F15364212000)
5
This SB Number
3
Dealer Code
© 2020 Toyota Motor Sales, USA
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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)
10. Flash reprogram the 4WD ECU.
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 Service Bulletin T-SB-0134-16, Techstream ECU Flash
Reprogramming Procedure, and flash the 4WD ECU with the NEW calibration file update.
11. Prepare and install the Authorized Modifications Label.
A. Using a permanent marker, enter the following information on the label:





4WD ECU 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 19. The Authorized Modifications Label is available through the MDC,
P/N 00451-00001-LBL.
12. Using Techstream, check for and clear ANY DTCs.
13. Inspect and adjust front wheel alignment.
Refer to TIS, applicable model and model year Repair Manual:

2019 – 2020 RAV4:
Suspension – Alignment/Handling Diagnosis – “Alignment / Handling Diagnosis: Front
Wheel Alignment: Adjustment”
14. Test-drive the vehicle and confirm the condition no longer exists.
© 2020 Toyota Motor Sales, USA