T-SB-0065-21

Rev1

August 9, 2021

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
September 14, 2021 Rev1:
 The Front Transfer Case Electro-magnetic Clutch Assembly Installation section 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-0019-20.
 The Parts Information and Repair Procedure sections have been updated.
Service Bulletin No. T-SB-0019-20 is obsolete, and any printed versions should be discarded.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 procedures 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.

© 2021 Toyota Motor Sales, USA

Page 1 of 26

T-SB-0065-21

Rev1

August 9, 2021

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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

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-0065-21

Rev1

August 9, 2021

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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

–

04000-46142

89630-42130
89630-42140

89630-42160

NOTICE
 The 4WD ECU should NOT be replaced as part of the Repair Procedure.
 Only ONE repair kit is needed. Both kits provide the same performance; use whichever repair
kit is more readily available.

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.

© 2021 Toyota Motor Sales, USA

T-SB-0065-21

Rev1

August 9, 2021

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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 16.10.017 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

© 2021 Toyota Motor Sales, USA

T-SB-0065-21

Rev1

August 9, 2021

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Abnormal Buzz/Groan Noise at 20 - 30 mph From Front Transfer Case
Confirmation 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 and complete the rest of the Repair Procedure in this bulletin.



NO — This bulletin does NOT apply. Continue diagnosis using the applicable
Repair Manual.

© 2021 Toyota Motor Sales, USA

T-SB-0065-21

Rev1

August 9, 2021

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Abnormal Buzz/Groan Noise at 20 - 30 mph From Front Transfer Case
Confirmation Procedure (continued)
Figure 1. Component Overview

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.

© 2021 Toyota Motor Sales, USA

T-SB-0065-21

Rev1

August 9, 2021

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Abnormal Buzz/Groan Noise at 20 - 30 mph From Front Transfer Case
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 2.

© 2021 Toyota Motor Sales, USA

T-SB-0065-21

Rev1

August 9, 2021

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Abnormal Buzz/Groan Noise at 20 - 30 mph From Front Transfer Case
Front Transfer Case Electro-magnetic Clutch Assembly Removal (continued)

B. Remove the five bolts and
electro-magnetic clutch
assembly cover.

Figure 3.
2

NOTICE

1

Do NOT remove the three bolts
attaching the ring gear assembly
housing to the transfer case.

2
2

NOTE
Gently remove the cover to prevent
the disconnect shaft from being
pulled out with the electro-magnetic