NHTSA ID Number: 11032480
Manufacturer Communication Number: T-SB-0028-26
TSB/Document Date: 2026-05-08
Summary
Some 2024 Grand Highlander and Grand Highlander Hybrid
vehicles may exhibit a rotational clicking noise from one or both front drive shaft assemblies when accelerating while making turns. This condition may occur without a grease leak present on the front drive shaft assemblies. An updated front drive shaft assembly is available to resolve this condition.
T-SB-0028-26
April 16, 2026
Rotational Clicking Noise From Front Drive Shaft
Assembly on Acceleration
Service
Category
Drivetrain
Section
Drive Shaf t/Propeller Shaf t
Market USA
Applicability
YEAR(S)
MODEL(S)
ADDITIONAL INFORMATION
2024
Grand Highlander, Grand
Highlander HV
SUPERSESSION NOTICE
The information contained in this bulletin supersedes Service Bulletin No. T-SB-0082-24.
• The Production Change Information, Warranty Information, Parts Information, and Required
Tools & Equipment sections have been updated.
Service Bulletin No. T-SB-0082-24 is obsolete and any printed versions should be discarded.
Introduction
Some 2024 Grand Highlander and Grand Highlander Hybrid vehicles may exhibit a rotational
clicking noise from one or both front drive shaft assemblies when accelerating while making turns.
This condition may occur without a grease leak present on the front drive shaft assemblies. An
updated front drive shaft assembly is available to resolve this condition. Follow the Repair
Procedure in this bulletin to address this condition.
Production Change Information
This bulletin applies to vehicles produced BEFORE the Production Change Effective VINs
shown below.
MODEL
PLANT
Grand
Highlander
TMMI
Grand
Highlander HV
VDS
PRODUCTION CHANGE
EFFECTIVE VIN
2WD
AAAA5
5TDAAAA5#RS018550
AWD
AAAB5
5TDAAAB5#RS066630
2WD
ABAA5
5TDABAA5#RS001736
ACAB5
5TDACAB5#RS029083
ADAB5
5TDADAB5#RS010532
DRIVETRAIN
AWD
© 2026 Toyota Motor Sales, USA
Page 1 of 5
T-SB-0028-26
April 16, 2026
Page 2 of 5
Rotational Clicking Noise From Front Drive Shaft Assembly on Acceleration
Warranty Information
OP CODE
DESCRIPTION
TIME
OFP
T1
T2
TC2601
R & R the Front Drive Shaf t Assembly
(One Side)
1.7
43420-0E3##*
43410-0E5##*
91
50
Opposite Side
0.3
Combo A
*Warranty claim MUST be submitted with the correct 10-digit OFP. Choose the correct OFP for the vehicle being repaired
by searching for the parts in the Electronic Parts Catalog using the VIN filter.
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.
Parts Information
PART NUMBER
PREVIOUS
NEW
43420-0E340
43420-0E341
43420-0E350
43420-0E351
43410-0E520
43410-0E521
43410-0E530
43410-0E531
43410-0E550
43410-0E551
90080-17238
90080-17238
PART NAME
QTY
Shaf t Assy, Fr Drive, LH*
1
Shaf t Assy, Fr Drive, RH*
1
Lock Nut (f or Fr Axle Shaf t)**
–
*Order the part(s) corresponding to the affected side and vehicle by searching in the Electronic Parts Catalog using the
VIN filter.
**Order one lock nut per affected front drive shaft assembly.
© 2026 Toyota Motor Sales, USA
T-SB-0028-26
April 16, 2026
Page 3 of 5
Rotational Clicking Noise From Front Drive Shaft Assembly on Acceleration
Required Tools & Equipment
REQUIRED EQUIPMENT
SUPPIER
PART NUMBER
QTY
ChassisEAR™ (or equivalent)
ADE
JSPSM06606
(JS Products)
1
NOTE
• A mechanic’s stethoscope or similar tool may be used in place of ChassisEAR™.
• ChassisEAR™ may be ordered by visiting the Toyota Tools and Equipment Program website at
Home – Service Resources – Toyota Tools and Equipment Program or by calling 1-800-368-6787.
REQUIRED EQUIPMENT
SUPPLIER
Techstream ADVI*
Techstream Lite
PART NUMBER
QTY
TSADVUNITECP
ADE
Techstream Lite (Green Cable)
TSLP3DLR01
TSLP2DLR01
*Essential SST.
NOTE
• Only ONE of the Techstream units listed above is required.
• GTS+ Sof tware version 2026.01.003.02 or later is required.
• Additional Techstream units may be ordered by calling Approved Dealer Equipment (ADE)
at 1-800-368-6787 or by visiting TIS – Diagnostics – Tools & Equipment – Techstream Order Portal.
© 2026 Toyota Motor Sales, USA
1
T-SB-0028-26
April 16, 2026
Page 4 of 5
Rotational Clicking Noise From Front Drive Shaft Assembly on Acceleration
Repair Procedure
1. Confirm the condition.
Does the vehicle exhibit a rotational clicking noise when accelerating while making turns?
•
YES — Continue to step 2.
•
NO — This bulletin does NOT apply. Continue diagnosis using the applicable
Repair Manual.
2. Place the vehicle on a lift and install the
ChassisEAR™ (or equivalent) on the front
knuckle assembly to help isolate the source
of the noise, as shown in Figure 1.
Figure 1.
1
1
ChassisEAR™ on the Front Knuckle Assembly
3. Test drive the vehicle.
Is one or both front drive shaft assemblies the source of the rotational clicking noise?
•
YES — Continue to step 4.
•
NO — This bulletin does NOT apply. Continue diagnosis using the applicable
Repair Manual.
4. Remove the affected front drive shaft assembly.
Refer to TIS, applicable model and model year Repair Manual:
•
2024 Grand Highlander:
Drivetrain – Drive Shaft / Propeller Shaft –
Front Drive Shaft Assembly (for T24A-FTS) – Removal
•
2024 Grand Highlander HV:
Drivetrain – Drive Shaft / Propeller Shaft –
Front Drive Shaft Assembly (for A25A-FXS) – Removal
© 2026 Toyota Motor Sales, USA
T-SB-0028-26
April 16, 2026
Page 5 of 5
Rotational Clicking Noise From Front Drive Shaft Assembly on Acceleration
Repair Procedure (continued)
5. Install the NEW front drive shaft assembly using the NEW lock nut.
Refer to TIS, applicable model and model year Repair Manual:
•
2024 Grand Highlander:
Drivetrain – Drive Shaft / Propeller Shaft –
Front Drive Shaft Assembly (for T24A-FTS) – Installation
•
2024 Grand Highlander HV:
Drivetrain – Drive Shaft / Propeller Shaft –
Front Drive Shaft Assembly (for A25A-FXS) – Installation
6. Perform steps 4 and 5 for the other front drive shaft assembly, if necessary.
7. Perform a grease distribution test drive by driving the vehicle continuously for 5 minutes
above 40 mph. If unable to perform this drive pattern, alternately drive the vehicle on a dyno
continuously for 5 minutes above 40 mph, if it is safe to do so.
NOTICE
Failure to perform the grease distribution test drive procedure may lead to joint damage
and false detection of the noise after replacement.
8. Confirm the condition is no longer present.
© 2026 Toyota Motor Sales, USA
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TSB/Document ID: T-SB-0028-26
Replacement Service Bulletin Number:
MFR Communication Date: 2026-04-16
MFR Internal Campaign ID/Software Version: T-SB-0028-26
Communication Type: Service Bulletin/Repair Instructions
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