NHTSA ID Number: 10214324
Manufacturer Communication Number: TSB002222
TSB/Document Date: 2022-06-21
Summary
TSB: 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.
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
T-SB-0022-22
March 17, 2022
Page 13 of 18
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
Page 14 of 18
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
T-SB-0022-22
March 17, 2022
Page 15 of 18
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
Page 16 of 18
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
March 17, 2022
Page 17 of 18
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
T-SB-0022-22
March 17, 2022
Page 18 of 18
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
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TSB/Document ID: TSB002222
Replacement Service Bulletin Number:
MFR Communication Date: 2022-03-14
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: POWER TRAIN
MFR Component System:
MFR Component Subsystem:
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