NHTSA ID Number: 10220192
Manufacturer Communication Number: TSB002222Rev1
TSB/Document Date: 2022-09-15
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
Rev1
March 17, 2022
Page 7 of 18
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 17.00.020 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
Rev1
March 17, 2022
Page 8 of 18
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
Rev1
March 17, 2022
Page 9 of 18
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
Rev1
March 17, 2022
Page 10 of 18
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 mismatch 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
Rev1
March 17, 2022
Page 11 of 18
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/
Grinding
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
Rev1
March 17, 2022
Page 12 of 18
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
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TSB/Document ID: TSB002222Rev1
Replacement Service Bulletin Number:
MFR Communication Date: 2022-06-24
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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