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Rear differential issues

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jwketchum

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Discussion starter · #1 ·
I have been getting a "turbine" whine out of the rear of my 2008 RAV4 for the last 15 or 20k miles -- currently at ~133k. Pitch is directly related to vehicle speed only. No noise when stopped. Pitch rises as speed increases.

Dealer has diagnosed it as a rear differential coupler problem and says it needs to be replaced. Car still runs fine, just kind of noisy.

What are the failure modes -- do I run the risk of some catastrophic failure -- standing by the interstate 200 miles from home waiting for AAA, or something worse? Is it time to abandon this car or should I shoot for 200k? No other problems of any consequence.

Thanks in advance for advice/suggestions.
 
Discussion starter · #3 ·
soulsurvives -- pitch does not change on turning.
avs -- I believe I had the fluid changed at 90k. Noise started sometime after that.
Thanks for your replies. 4WD is still operational. If the only consequence of failure is losing AWD/4WD, then perhaps it is not that big an issue.
 
#4 ·
Drain and inspect

I'm with avs. Change fluid and and see if it helps. My dealer shop says change the rear diff fluid every 35k-miles, so you are in that time frame.

There is a great write-up on DIY rear diff and transfer case fluid changes by vanib:
http://www.rav4world.com/forums/99-...forums/99-4-3-mechanical/90542-rear-differential-transfer-case-gear-lube-2.html

Some tips from the procedure might confirm what dealer says:
when you (or the shop) drain the fluid, measure it. (Maybe it was just low.) Should be around .5 liter. Check the color and for excessive metal shavings. Check the magnetic drain bolt for metal shavings.

Clean fluid would likely extend the life of those gears.

Assuming it is a bad differential coupler, did your dealer estimate a cost for the repair? Must be an arm and/or a leg if you are considering to let it fail rather than fix. What is their opinion if you let it go?
 
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#5 ·
Another thing to try is disconnecting the 4WD ECU which eliminates any power to the electro-controller on the front of the rear differential. It's one of the two modules mounted in front of the glove box, can't remember right or left. The other is the TPMS. Drop the box and pull the plug on one. If the Tire pressure warning comes on you have the wrong one.
 
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Discussion starter · #6 ·
Thanks, RAVN4RED. Estimate for "Rebuild Viscous Coupler" of $1028.79. This came with a copy of a page from T-SB-0080-13 "Rear Differential Coupling Growl Noise." The $1k repair cost would be ok, if I understood the problem and had confidence that the diagnosis is correct. At this point in the life of the car, I would prefer incremental steps like disabling the ECU and changing the differential fluid, before committing to a $$$$ repair.
 
#7 ·
soulsurvives said:
Since you get noise at all speeds I doubt disconnecting power to the coupler is gonna make the noise stop.....I would try changing the fluid but if it's a worn bearing in there nothing is gonna get rid of the noise other than replacing it.
Click to expand...
Agreed. The ECU disconnect is just an easy diagnostic. And it may take the "pressure" off whatever's causing the noise to make it last longer. Oil change is next.

jwketchum, seems like you also agree. Let us know how it goes.
 
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#11 ·
T-SB-0080-13 completed

Took mine in yesterday for this costly repair. The sound got louder over the course of about 500 miles and I got nervous. Total cost after a 10% discount coupon and waiving the diagnosis fee, $1953.49.

I asked to see the part while it was up on the rack. Shiny new one was already in place; culprit was on the bench. You can't actually see the guts, but they described it as having a bunch of bearings. Because of the location on the car and how it was essentially in the middle of the whole drivetrain, they said that the noise it creates travels to each wheel, so you can't ever pin down where the noise is at like you can with wheel bearings. Whatever, I just wanted my car back...

Total shop time not including lunch or the free wash to get the salt off was about 5 hours. In the meantime, they gave me a TRD Tacoma that was fun to drive until I had to replace the burned fuel...

Question though: I have been trying to find the original factory part number for the coupling sub-assembly that was replaced to see if it was a different part number. Can anybody help locate this? The new one is 41303-42022, coupling sub-assy.

UPDATE: Just found it. The original part number appears to be 41303-42020 according to: http://www.toyodiy.com/parts/ . Neat site to find part numbers by VIN or by searches. Hadn't come across that in my hours of searching last night...
 
#12 ·
jwketchum said:
Thanks, RAVN4RED. Estimate for "Rebuild Viscous Coupler" of $1028.79. This came with a copy of a page from T-SB-0080-13 "Rear Differential Coupling Growl Noise."
Click to expand...
Interesting. I would like to see the full text TSB. The only part I found was:

THE REAR DIFFERENTIAL COUPLING, WHEN DRIVING SOME VEHICLES, MAY EXHIBIT A GROWL NOISE, DUE TO CONTAMINATION TO FRONT BEARING. MODEL 2006-2012 RAV4 (42WD). ( NHTSA ITEM NUMBER - 10052631 )
Click to expand...
 
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#14 ·
Jwketchum... Check with your dealer again... I had the same thing happening with my 2009 RAV4, around the same mileage as well. They diagnosed the same thing as the VISCOUS COUPLER, and it would need to be replaced. They quoted me $1240CAD. Went to a couple garages to try and get a lower price,and they said they would need to keep the truck overnight to resolve the issue. That wasn't happening. My dealership called back and told me the replacement was covered under an extended warranty. Had it fixed today, rear whine is gone :)
 
#15 ·
Canrav4 - is your Rav a 4 cyl. or a 6 cyl.? would you be kind enough to post a photo of your invoice to confirm the bulletin number?

I just came back from the dealer & seem to have the same issue. I'm out of warranty by 2 months & the advisor told me he would contact Toyota Canada next week to see if they would cover me. He also mentioned a TSB # 4005 that I have not been able to find online.

Thanks for your help!
 
#16 ·
chupster said:
Canrav4 - is your Rav a 4 cyl. or a 6 cyl.? would you be kind enough to post a photo of your invoice to confirm the bulletin number?



I just came back from the dealer & seem to have the same issue. I'm out of warranty by 2 months & the advisor told me he would contact Toyota Canada next week to see if they would cover me. He also mentioned a TSB # 4005 that I have not been able to find online.



Thanks for your help!
Click to expand...

Chupster... I have a 4 cyl.... I checked my invoice. Try looking up WAB 1290, it's the only thing I can find on my invoice... I'll try to figure out how to post my receipt and post shortly


Sent from AutoGuide.com Free App
 
#17 ·
Thanks! mine is also a 4 cyl 2009, my second Rav by the way, had an 02 that served me well for 8 yrs....I'm starting to get nervous with the new(old) toy!!

You can send me the photo at chupster98 -AT- gmail.com.

Thanks again!
 
#20 ·
Our 2010 RAV4 started this winning sound about a month ago and Fiore Toyota told us they would have to replace the complete differential assy. for $2800.00. I will repair it in due time, till then this piece of junk will sit in the garage and we will drive our Land Rovers
 
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