NHTSA ID Number: 10173739
Manufacturer Communication Number: T-SB-0019-20
TSB/Document Date: 2020-04-13
Summary
TSB: 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 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.
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TSB/Document ID: T-SB-0019-20
Replacement Service Bulletin Number:
MFR Communication Date: 2020-03-03
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: EQUIPMENT ADAPTIVE/MOBILITY
MFR Component System:
MFR Component Subsystem:
Previous TSB | Next TSB |
T-SB-0019-20
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
RAV4
ADDITIONAL INFORMATION
SUPERSESSION NOTICE
The information contained in this bulletin supersedes Service Bulletin No. T-SB-0065-19.
Production Change Information has been updated, changing VIN information.
Service Bulletin No. T-SB-0065-19 is obsolete and any printed versions should be discarded.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 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 model year RAV4 Adventure and Limited grade vehicles with
torque vectoring AWD system.
© 2020 Toyota
Motor Sales, USA
Page 1 of 16
T-SB-0019-20
March 3, 2020
Page 2 of 16
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. 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#KW080109
TMMC - W
RAV4
AWD
2T3J1RFV#KW080109
Takaoka
JTMN1RFV#KJ023026
Shokki #1
JTMN1RFV#KD041318
Shokki #2
JTMN1RFV#KD522367
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.
© 2020 Toyota Motor Sales, USA
T-SB-0019-20
March 3, 2020
Page 3 of 16
Abnormal Buzz/Groan Noise at 20 - 30 mph From Front Transfer Case
Parts Information
PART NUMBER
PART NAME
QTY
Electro-magnetic Clutch Assy
1
1
Transaxle Refill/Overflow Plug Gasket*
2
90341-18035
1
12157-10010
Front Transfer Case Refill/Drain Plug Gasket*
2
90311-35056
1
Nut, Lock*
1
90119-10461
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
41406-42010
41406-42012
90301-99240
90430-18008
90430-A0003
90177-22001
90080-17238
*Nonreusable part.
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 14.30.022 or later is required.
ChassisEAR™ and Additional Techstream units may be ordered by calling Approved Dealer Equipment
(ADE) at 1-800-368-6787.Additional Techstream units may be ordered by calling Approved Dealer
Equipment (ADE) at 1-800-368-6787.
© 2020 Toyota Motor Sales, USA
T-SB-0019-20
March 3, 2020
Page 4 of 16
Abnormal Buzz/Groan Noise at 20 - 30 mph From Front Transfer Case
Repair Procedure
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
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 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.
© 2020 Toyota Motor Sales, USA
T-SB-0019-20
March 3, 2020
Page 5 of 16
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
© 2020 Toyota Motor Sales, USA
T-SB-0019-20
March 3, 2020
Page 6 of 16
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
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
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