NHTSA ID Number: 10169438
Manufacturer Communication Number: T-SB-0065-19_Rev
TSB/Document Date: 2019-12-16
Summary
TSB: 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. 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.
16
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
Page 7 of 16
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
June 14, 2019
Page 8 of 16
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
Page 9 of 16
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
June 14, 2019
Page 10 of 16
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
June 14, 2019
Page 11 of 16
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
Rev1
June 14, 2019
Page 12 of 16
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
Page 13 of 16
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
Rev1
June 14, 2019
Page 14 of 16
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
T-SB-0065-19
Rev1
June 14, 2019
Page 15 of 16
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
Rev1
June 14, 2019
Page 16 of 16
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
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TSB/Document ID: T-SB-0065-19_Rev
Replacement Service Bulletin Number:
MFR Communication Date: 2019-11-20
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: EQUIPMENT
MFR Component System:
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