TSB002222

T-SB-0022-22
March 17, 2022
Abnormal Noise From the AWD Dynamic Torque
Vectoring Disconnect System
Service
Category
Drivetrain
Section
Axle/Differential
Market USA
Applicability
YEAR(S)
MODEL(S)
ADDITIONAL INFORMATION
2019 - 2020
RAV4
VDS(s): J1RFV, N1RFV
SUPERSESSION NOTICE
 The information contained in this bulletin supersedes Service Bulletin No. T-SB-0067-20.
 The Introduction, Warranty Information, Parts Information, and Required Tools & Equipment
sections have been updated.
 The Production Change Information and Repair Procedure sections have been updated.
 The Calibration Information, Confirmation Procedures, Noise Confirmation Procedure, Transfer
Assembly Replacement Procedure, Rear Differential Carrier Assembly Replacement Procedure,
and 4WD ECU Reflash Procedure sections have been added.
Service Bulletin No. T-SB-0067-20 is obsolete and any printed versions should be discarded.
© 2021 Toyota Motor Sales, USA
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T-SB-0022-22
March 17, 2022
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Abnormal Noise From the AWD Dynamic Torque Vectoring Disconnect System
Introduction
Some 2019 – 2020 model year RAV4 Adventure and Limited grade AWD vehicles may exhibit an
abnormal noise from the vehicle’s AWD Dynamic Torque Vectoring Disconnect system from either
the transfer assembly or rear differential carrier assembly when accelerating from a stop and/or on
deceleration after driving the vehicle for 15 minutes or more. This condition occurs with “Normal”
drive mode selected during disconnect/connect timing of the AWD system.
Follow the procedures in this bulletin to address these conditions.
NOTE
This Service Bulletin ONLY applies to 2019 – 2020 model year RAV4 Adventure and Limited grade
vehicles with torque vectoring AWD Dynamic Torque Vectoring Disconnect system.
Production Change Information
Front Transfer Assembly Production Change Information
This bulletin applies to vehicles produced BEFORE the Production Change Effective VINs
shown below.
Table 1. Front Transfer Assembly Production Change Information
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
© 2021 Toyota Motor Sales, USA
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March 17, 2022
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Abnormal Noise From the AWD Dynamic Torque Vectoring Disconnect System
Production Change Information (continued)
Rear Differential Carrier Assembly Production Change Information
This bulletin applies to vehicles produced BEFORE the Production Change Effective serial number
shown below.
Table 2. Rear Differential Carrier Assembly Production Change Information
MODEL
PLANT
DRIVETRAIN
PRODUCTION CHANGE EFFECTIVE SERIAL NUMBER
AWD
20E15F1013
TMMC - C
TMMC - W
RAV4
Takaoka
Shokki #1
Shokki #2
1. Locate the rear differential carrier assembly serial number, as shown in the figure below.
Figure 1. Rear Differential Carrier Assembly Differential Front View
1
2
1
Propeller Shaft
2
Rear Differential Carrier Assembly Serial Number
© 2021 Toyota Motor Sales, USA
T-SB-0022-22
March 17, 2022
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Abnormal Noise From the AWD Dynamic Torque Vectoring Disconnect System
Production Change Information (continued)
Rear Differential Carrier Assembly 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 Carrier Assembly Serial Number Breakdown
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
Warranty Information
OP CODE
DESCRIPTION
TIME
TC1906
R & R Differential Carrier Assembly
for Torque Vectoring Differential
5.0
OFP
T1
T2
91
19
41110-#####*
Combo A
(Differential)
Reprogram 4WD ECU
0.5
TC1907
R & R Front Transfer Case Assembly for
Torque Vectoring with Air Conditioning
6.4
Combo A
(Transfer
Assembly)
36100-#####*
Reprogram 4WD ECU
0.5
*Warranty claim MUST be submitted with the correct 10-digit OFP. Choose the correct OFP for the vehicle being
repaired by searching for the parts in the Electronic Parts Catalog using the VIN filter.
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.
© 2021 Toyota Motor Sales, USA
T-SB-0022-22
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Abnormal Noise From the AWD Dynamic Torque Vectoring Disconnect System
Parts Information
For Rear Differential Carrier Assembly Replacement
PART NUMBER
PREVIOUS
PART NAME
QTY
Carrier Assy, Differential
1
NEW
41110-42050
41110-42051
41110-42053
41110-42052
90119-12453
2
90119-12455
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
12157-10010
Gasket, Drain Plug
1
00451-00001-LBL
Authorized Modifications Labels
1
Computer Assy, 4WD
–
89630-42130
89630-42140
89630-42160
89630-42161
*Nonreusable part.
NOTE
 The 4WD ECU should NOT be replaced as part of the Repair Procedure.
 Authorized Modifications Labels may be ordered in packages of 25 from the Materials
Distribution Center (MDC) through Dealer Daily – Parts – Dealer Support Materials Orders.
© 2021 Toyota Motor Sales, USA
T-SB-0022-22
March 17, 2022
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Abnormal Noise From the AWD Dynamic Torque Vectoring Disconnect System
Parts Information (continued)
For Transfer Assembly Replacement
PART NUMBER
PART NAME
QTY
Transfer Assy
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
12157-10010
Gasket, Drain Plug
1
Computer Assy, 4WD
–
PREVIOUS
NEW
36100-42170
36100-42172
36100-42171
89630-42130
89630-42140
89630-42160
89630-42161
NOTE
 The 4WD ECU should NOT be replaced as part of the Repair Procedure.
 Authorized Modifications Labels may be ordered in packages of 25 from the Materials
Distribution Center (MDC) through Dealer Daily – Parts – Dealer Support Materials Orders.
© 2021 Toyota Motor Sales, USA
T-SB-0022-22
March 17, 2022
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Abnormal Noise From the AWD Dynamic Torque Vectoring Disconnect System
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 16.30.011 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.
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.
© 2021 Toyota Motor Sales, USA
T-SB-0022-22
March 17, 2022
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Abnormal Noise From the AWD Dynamic Torque Vectoring Disconnect System
Calibration Information
GRADE
ECU
Adventure
4WD
Limited
CALIBRATION ID
PREVIOUS
NEW
F15364209200
F15364210000
F15364212000
F15364212100
Procedures

Noise Confirmation Procedure .................................................................................................. 9

Transfer Assembly Replacement Procedure ............................................................................ 15

Rear Differential Carrier Assembly Replacement Procedure .................................................... 15

4WD ECU Reflash Procedure .................................................................................................. 17
© 2021 Toyota Motor Sales, USA
T-SB-0022-22
March 17, 2022
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Abnormal Noise From the AWD Dynamic Torque Vectoring Disconnect System
Noise Confirmation Procedure
1. Does the vehicle exhibit one of the following abnormal noises from the AWD Dynamic Torque
Vectoring Disconnect system from either the transfer assembly or rear differential carrier
assembly 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 either the transfer assembly or the rear
differential carrier 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 and some 2020 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.

YES — Continue to step 2.

NO — This bulletin does NOT apply. Continue diagnosis using the applicable
Repair Manual.
2. Does the vehicle have a production date BEFORE September 17, 2019?

YES — Go to step 4.

NO — Continue to step 3.
3. Confirm the location of the noise in the vehicle.
A. Is the noise exhibited from the transfer assembly?
 YES — Go to step 7.
 NO — Continue to substep B.
B. Is the noise exhibited from the rear differential carrier assembly?
 YES — Go to the Rear Differential Carrier Assembly Replacement Procedure.
 NO — This bulletin does NOT apply. Continue diagnosis using the applicable
Repair Manual.
© 2021 Toyota Motor Sales, USA
T-SB-0022-22
March 17, 2022
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Abnormal Noise From the AWD Dynamic Torque Vectoring Disconnect System
Noise Confirmation Procedure (continued)
4. Use Techstream to review the vehicle’s 4WD data list and confirm 4WD connect/
disconnect timing.
A. Connect the vehicle to Techstream and navigate to Techstream – 4WD ECU – Data List.
B. While driving the vehicle with Techstream still connected, review the highlighted
items shown below.
CAUTION
Recommend using an assistant to drive the vehicle while observing these items
in Techstream.
Figure 3. 4WD ECU Data List (Overview)
5
1
2
3
6
4
1
Front/Rear Axle Coupling Clutch Current
4
Front/Rear D-module Switching Status
2
Front/Rear Axle Coupling Clutch Position
Sensor Status
5
Front/Rear Dog Solenoid Current
Request Value
3
Propeller Shaft Revolution
6
Front/Rear Dog Connect Judgement Flag
NOTE
The miss match condition can occur as both Connect/Disconnect or Disconnect/Connect.
5. Referring to Figure 3 do any of the noise conditions listed in step 1 exist during
connect/disconnect timing between the front and rear electromagnetic clutch at ANY speed?

YES — Continue to step 6.

NO — This bulletin does NOT apply. Continue diagnosis using the applicable
Repair Manual.
© 2021 Toyota Motor Sales, USA
T-SB-0022-22
March 17, 2022
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Abnormal Noise From the AWD Dynamic Torque Vectoring Disconnect System
Noise Confirmation Procedure (continued)
6. Determine the repair direction by identifying the cause component using the list of possible
scenarios shown in the table below.
Table 3. Failure Mode
SCENARIO
FAILED
PART
Front
Electromagnetic
Transfer
Clutch (EMC)
Assembly
Insufficient
Torque
IDENTIFICATION OF FAILED PART
PART
DATA LIST SCENARIO
GENERATING DESCRIPTION
(TO CONFIRM, USE TECHSTREAM
ABNORMAL
OF
4WD DATA LIST AS SEEN
NOISE
CONDITION
IN FIGURE 1)
Rear
Differential
Carrier
Assembly
Ratchet/
Griding
Transfer
Assembly
Bang/
Thump
RECOMMENDED
PART
REPLACEMENT
 Front Axle Coupling Clutch
Current About 6 amps Just
Before Abnormal
Noise Occurs:
 Front Axle Coupling
Clutch Position Sensor
Status: Disconnect
 Rear Axle Coupling
Clutch Position Sensor
Status: Connect
 Front Axle Coupling Clutch
Current About 6 amps Just
Before Abnormal
Noise Occurs:
 Front Axle Coupling
Clutch Position Sensor
Status: Connect
 Rear Axle Coupling
Clutch Position Sensor
Status: Disconnect
 Front Axle Coupling Clutch
Current About 6 amps Just
Before Abnormal
Noise Occurs
© 2021 Toyota Motor Sales, USA
Replace the
Transfer
Assembly
T-SB-0022-22
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Abnormal Noise From the AWD Dynamic Torque Vectoring Disconnect System
Noise Confirmation Procedure (continued)
Table 3. Failure Mode (continued)
SCENARIO
Rear EMC
Insufficient
Torque
Front
EMC
Negative
Gradient
FAILED
PART
Rear
Differential
Carrier
Assembly
Transfer
Assembly
(EMC)
IDENTIFICATION OF FAILED PART
PART
DATA LIST SCENARIO
GENERATING DESCRIPTION
(TO CONFIRM, USE TECHSTREAM
ABNORMAL
OF
4WD DATA LIST AS SEEN
NOISE
CONDITION
IN FIGURE 1)
Transfer
Assembly
Bang/
Thump
or
Ratchet/
Grinding
 Rear Axle Coupling Clutch
Current: About 6 amps
and Propeller Shaft
Rotation Speed is Zero or
Small Just Before
Abnormal Noise Occurs:
 Front Axle Coupling
Clutch Position Sensor
Status: Disconnect
 Rear Axle Coupling
Clutch Position Sensor
Status: Connect
Rear
Differential
Carrier
Assembly
Bang/
Thump
 Rear Axle Coupling Clutch
Current: About 6 amps
Just Before Abnormal
Noise Occurs
Transfer
Assembly
Buzz/
Groan
Rear EMC
Negative
Gradient
Rear Differential
Carrier Assembly
Rear EMC
Large
Torque
Gradient
Single,
Double,
or
Triple
Clunk
 Abnormal Noise Occurs
When Front EMC
Current ON
 No Switching Error
DTC set
 Front Abnormal Noise
 Abnormal Noise Occurs
When Rear EMC
Current ON
 No Switching Error
DTC set
 Rear Abnormal Noise
 Abnormal Noise Occurs
When Rear EMC current
ON or Propeller Shaft
Rotation Speed
is Increasing
 No Switching Error
DTC set
 Rear Abnormal Noise
© 2021 Toyota Motor Sales, USA
RECOMMENDED
PART
REPLACEMENT
Replace
the Rear
Differential
Carrier
Assembly
Refer to
T-SB-0065-21
Replace
the Rear
Differential
Carrier
Assembly
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Abnormal Noise From the AWD Dynamic Torque Vectoring Disconnect System
Noise Confirmation Procedure (continued)
Table 3. Failure Mode (continued)
SCENARIO
Transfer
Piston
Foreign
Matter
Biting
FAILED
PART
Transfer
Assembly
IDENTIFICATION OF FAILED PART
PART
DATA LIST SCENARIO
GENERATING DESCRIPTION
(TO CONFIRM, USE TECHSTREAM
ABNORMAL
OF
4WD DATA LIST AS SEEN
NOISE
CONDITION
IN FIGURE 1)
Rear
Differential
Carrier
Assembly
Bang/
Thump
 Front Position Sensor
Status: “Disconnect” Just
Before Abnormal
Noise Occurs:
 Front Axle Coupling
Clutch Position Sensor
Status: Disconnect
 Rear Axle Coupling
Clutch Position Sensor
Status: Connect
RECOMMENDED
PART
REPLACEMENT
Replace
the Transfer
Assembly
A. Did the condition meet the criteria for one of scenarios described above in Table 3?
 YES — Continue to substep B.
 NO — This bulletin does NOT apply. Continue diagnosis using the applicable
Repair Manual.
B. Replace the recommended part based on the repair recommendation.
 Transfer Assembly — Go to the Transfer Assembly Replacement Procedure.
 Rear Differential Carrier Assembly — Go to the
Rear Differential Carrier Assembly Replacement Procedure.
© 2021 Toyota Motor Sales, USA
T-SB-0022-22
March 17, 2022
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Abnormal Noise From the AWD Dynamic Torque Vectoring Disconnect System
Noise Confirmation Procedure (continued)
7. Does the vehicle exhibit an abnormal noise from the transfer assembly during one or both
of the following conditions as described in step 1?
NOTE
 Use ChassisEAR™ to confirm the noise is coming from the transfer 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.
CAUTION
Recommend using an assistant to drive the vehicle while observing these items
in Techstream.

While driving when accelerating from a stop during AWD system disconnect timing.

While driving on deceleration during AWD system connect timing.
HINT
On 2019 and some 2020 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.

YES — Continue to step 8.

NO — This bulletin does NOT apply. Continue diagnosis using the applicable
Repair Manual.
8. Does the vehicle exhibit an abnormal buzz/groan noise from the transfer assembly
when accelerating from a stop and/or on deceleration after driving the vehicle for 15 minutes
or more?
Refer to the buzz/groan noise example video link:
Buzz/Groan Noise Example Video

YES — Refer to T-SB-0065-21.

NO — Continue to the Transfer Assembly Replacement Procedure.
© 2021 Toyota Motor Sales, USA
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March 17, 2022
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Abnormal Noise From the AWD Dynamic Torque Vectoring Disconnect System
Transfer Assembly Replacement Procedure
1. Remove the transfer assembly.
Refer to TIS, applicable model and model year Repair Manual:

2019 / 2020 RAV4:
Drivetrain – Transfer/4WD/AWD – “GF2A (Transfer / 4WD / AWD):
Transfer Assembly: Removal”
2. Install the NEW transfer assembly.
Refer to TIS, applicable model and model year Repair Manual:

2019 – 2020 RAV4:
Drivetrain – Transfer/4WD/AWD – “GF2A (Transfer / 4WD / AWD):
Transfer Assembly: Installation”
3. Go to the 4WD ECU Reflash Procedure.
Rear Differential Carrier Assembly Replacement Procedure
1. Confirm the rear differential carrier assembly production date is BEFORE May 15, 2020.
Does the differential serial number show a production date BEFORE the effective serial
number in the Production Change Information section?

YES — Continue to step 2.

NO — This bulletin does NOT apply. Continue diagnosis using the applicable
Repair Manual.
2. Remove 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”
© 2021 Toyota Motor Sales, USA
T-SB-0022-22
March 17, 2022
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Abnormal Noise From the AWD Dynamic Torque Vectoring Disconnect System
Rear Differential Carrier Assembly Replacement Procedure (continued)
3. Disassemble the rear differential carrier assembly.
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”
NOTE
ONLY steps 1 – 4 and 12 – 13.
4. Reuse the side couplers/harness and brackets from the original equipment removed.
5. Reassemble the rear differential carrier assembly.
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): Reassembly”
NOTE
ONLY steps 17 – 18 and 25 – 28.
6. Reinstall the rear differential carrier assembly.
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): Installation”
© 2021 Toyota Motor Sales, USA
T-SB-0022-22
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Abnormal Noise From the AWD Dynamic Torque Vectoring Disconnect System
4WD ECU Reflash Procedure
1. 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 4.

NO — Continue to step 2.
Figure 4. 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., 89630-42161)
4
Date Completed
2
New Calibration ID (e.g., F15364212000)
5
This SB Number
3
Dealer Code
© 2021 Toyota Motor Sales, USA
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Abnormal Noise From the AWD Dynamic Torque Vectoring Disconnect System
4WD ECU Reflash Procedure (continued)
2. 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 T-SB-0134-16, Techstream ECU Flash Reprogramming
Procedure, and flash the 4WD ECU with the NEW calibration file update.
3. 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 4. The Authorized Modifications Label is available through the MDC,
P/N 00451-00001-LBL.
4. Using Techstream, check for and clear ANY DTCs.
5. Test-drive the vehicle and confirm the condition no longer exists.
© 2021 Toyota Motor Sales, USA