Can you give more details on what I am looking at on these photos?
Is it the rear drive unit? Is it the front transaxle?

 

Rear! I wrote more details

 

thats a picture of what toyota do on new rav4

2021-2022

 

Well you guys will put salt on your roads. Not a problem down under - unless we drive along the beach. I do not see how this is a warranty issue.

 

Yeah? That's it? Doesn't happen in Australia therefore not an issue? Oh okay then.

 

... hybrid malfunction message. I did a inspection at the dealer! At the rear drive unit the wire is in really bad shape and toyota dont want put on my hybrid 100 000 miles warrenty!

+1 on post #5 @Maudie. Your "salty" winter roads caused the corrosion.

YES, wire is corroded. BUT, it is NOT a manufacturing defect. Sorry.
3-4years of salt and clearly NOTregularly rinsing the undercarriage during those 3-4 harsh salty winters took its tool on the wiring connector/harness.

1) IF you were in the USA, you would be able to call Toyota to complain, and/or ask for "Goodwill" service. This is 100% discretionary by Toyota. The determining factors seem to be how far out of warranty you are, and if you have been doing PAID service at a Toyota dealership. If you are NOT too far outside of warranty (time/mileage) and you have been doing a lot of paid service, your chances of getting "Goodwill" are good. Again, it is 100% at Toyota's discretion. You should call your dealership and Toyota CAN to beg/plead your case.
2) The part # you provide is about $1600-$1700 range, depending on which online Toyota dealership one buys it from. A used part from a RAV4 hybrid at a salvage yard would be your cheapest option. Online sites that sell used parts would be your second cheapest option.

It will be a pain to replace that harness, but it can be done DIY, if you have the inclination, skills, tools, and Techstream.

Good luck to you.

 

Is this the same connector that is used on the '20, '21, and now '22 Rav 4 hybrid? And there's an admonition in the owner's manual (post #11) that one shouldn't power wash the underside of the vehicle?

I think its the same!

 

Although salt is the probable cause of the issue it looks like they could have done more to properly seal the cable, especially the braided shield.
This is by the way exactly why I have to bottom rinsed when going through the carwash.

 

Definitely should be replaced under hybrid system or power train warranty. All undercarriage electrical must meet or exceed IP 66 requirements. This does not! Manufacturing defect, design flaw? Who knows but failed due to no fault of owner.

 

failed due to no fault of owner.

I bet there is a section on maintaining care & appearance of vehicle by washing/rinsing underside of vehicle, esp when exposed to mud/snow/salt.

If OP did so w/ regularity, OP would have never posted this unfortunate experience.

 

IP ratings do not say anything about salt water.
IP 66 is protected against dust and water jets from all directions. The thing is, this isn't the result from direct water jets.

 

IP ratings do not say anything about salt water.
IP 66 is protected against dust and water jets from all directions. The thing is, this isn't the result from direct water jets.

It is a direct result of salt laden water ingression causing corrosion and failure. Simple as that. Toyota should have done a better job of sealing it.

 

This is a terrible design, plain and simple. Stop making excuses for the Toyota engineers.

 

Of course you NEVER want to use a high pressure washer on a car due to risk of damage to paint and other components.

A garden hose would be sufficient.

 

Hi

2019 rav4 hybrid with 80 000 miles on it! Im leaving cold Canada and 2 weeks ago i got hybrid malfunction message. I did a inspection at the dealer! At the rear drive unit the wire is in really bad shape and toyota dont want put on my hybrid 100 000 miles warrenty!

Im the only one who that thing happen?
What you did to get paid the total bill?

Wire part number is 821h10r011 4800$ CAN + Job time $
View attachment 176398 View attachment 176401
View attachment 176400

Friend of mine had his rear HV cable replaced last winter. Warranty!

 

Did his have 80k miles on it?

 

I agree with the others saying this is on Toyota and that it should be better sealed/protected. Simply "rinsing" your undercarriage isn't enough to get rid of the salt and magnesium chloride, and good luck trying to rinse out this exact spot. It should be better sealed/protected, period. Terrible design.

 

I haven't been able to take a good look but it seems like the connection is different from the 4.4 Hybrid where the connections seem to be higher up on the case of the rear drive unit.
I will take a better look and possibly take a picture when I can.

 

This is the best I could do for now.
The connections on the 4.4 seem to be at a better location.
They are at the left side (drivers side) of the unit, all the way at the top.
It seems that there is hardly any spray getting up there.

So the change that Toyota made for the new rear drive unit hasn't turned out that well in this regard.

 

This is the best I could do for now.
The connections on the 4.4 seem to be at a better location.
They are at the left side (drivers side) of the unit, all the way at the top.
It seems that there is hardly any spray getting up there.

So the change that Toyota made for the new rear drive unit hasn't turned out that well in this regard.

Thanks for confirming the 4th gen hybrid MGR connector may not be as susceptible to corrosion.

Much appreciated.
-----
But if anyone knows otherwise, please let 4th gen hybrid owners know as I was oblivious to this 5th gen issue until someone posted about it on a Car Care Nut YouTube video (streaming type) this week.

 

Omg!
that’s a design flaw.
I am sorry about your mishap.
How can we perform a maintenance to prevent this?

 

The only solution is to clean it often when roadsalt is used.

 

If I disconnect the connector to clean it on a car that’s turned off will I trip any codes?
what To clean it with? Mass airflow sensor cleaner?
would applying putty around connector to seal it help?

 

If I disconnect the connector to clean it on a car that’s turned off will I trip any codes?
what To clean it with? Mass airflow sensor cleaner?
would applying putty around connector to sea it help?

I would advise against using putty, or anything else that wouldn't create a perfect seal. It could just trap moisture and deicing chemicals in there. Kinda like this concept www.youtube.com/watch?v=nXvl9nt57Kg and also like his most recent brake hose video

I like his videos, I've seen him use fluid film often on exposed connections and grote ultra seal sometimes too (vid). With that said... I'd be a little reluctant to apply anything to a high voltage connection like that at this point in time. Toyota is aware of the issue, I bet they'll come out with some sort of a fix or be willing to apply some sort of officially approved coating to it.

 

Is this the same connector that is used on the '20, '21, and now '22 Rav 4 hybrid? And there's an admonition in the owner's manual (post #11) that one shouldn't power wash the underside of the vehicle?

 

Toyota already kissed me goodbye when I passed 36k miles.

 

If that's not a warranty item I'm one and done on Hybrids. All it takes is a few drops of intrusion and capillary action takes over. Does anyone know if this is covered with an extended warranty?

 

The hybrid warrenty of toyota dont cover the wire !

 

that's the thing. hybrids are fun but when they break it costs a fortune to fix. I went to a dealer recently for checkup and he says 150$, oh sorry its 320$ cause you have a hybrid. keeping a hybrid looong term is a gamble. makes me think now I own a Mercedes.
at least a splash guard would help. and periodic cleaning.

 

Your first mistake was taking it into the dealership. They love people who don't know anything, so they can charge whatever they want! Go on Facebook and ask the community for a good local mechanic.

 

it appears to me it is the transition from stranded conductors to copper pins inside the plug is rusting. there is no way to clean it mechanically.

2k$ for a wire and connector . replace every 2-3 years? this thread will be the new 'fuel tank fill issue'
what if they only crimped the connection (transition) from braids to pins. owners in snowy areas are doomed.
At least They could have used a weatherproof gel to keep salty water out. like in outdoor wire nuts. I am a master electrician so I have an idea how messed up this episode will be. this is a high amperage and high voltage connection which makes it messed up squared not multiplied. R=E2/P. resistance is equal to voltage squared divided by power. I gotta calm down.

I have an idea. open the plastic. clean with some spray (mass airflow cleaner) or 99% isopropyl alcohol and plastic brush and squirt CRC rust inhibitor there to repel salty water.
Another thing is how to do it safely. 200 DC is really dangerous voltage and even residual Voltage may be harmful. hopefully somebody here knows how to disconnect power and safely work on high voltage dc in cars.

 

I am a sceptic that this is covered under powertrain warranty. This issue looks like 'electrical' part of the car . Powertrain I find to be mechanical, possibly including rear electric motor but excluding electrical harness.

 

From Kia: “A powertrain is an assembly of every component that thrusts your car into motion. It includes engine, transmission, driveshaft, axles, and differential.”

On an ICE only car, the powertrain is anything that takes power from the power source to the wheels.

Why is this not the same?

 

Read the op’s 1st paragraph

2019 rav4 hybrid with 80 000 miles on it! My car is 28 months old and Im leaving cold Canada. 2 weeks ago i got hybrid malfunction message. I did a inspection at the dealer! At the rear drive unit the wire is in really bad shape and toyota dont want put on my hybrid 100 000 miles warrenty!

Better to investigate this more closely cause the devil is in the details


Toyota Certified Used Vehicle Warranty

Every Toyota certified used vehicle comes with a 12-month/12,000 mile limited comprehensive warranty starting at the date of purchase. Toyota certified used hybrid vehicles also still receive the 8-year/100,000 mile Factory Hybrid Vehicle Battery Warranty. Toyota certified used vehicles also receive a 7-year/100,000 limited powertrain warranty. Components covered by this warranty include engine components, manual transmission, automatic transmission, axle assembly components and hybrid components.

 

Read the op’s 1st paragraph

2019 rav4 hybrid with 80 000 miles on it! My car is 28 months old and Im leaving cold Canada. 2 weeks ago i got hybrid malfunction message. I did a inspection at the dealer! At the rear drive unit the wire is in really bad shape and toyota dont want put on my hybrid 100 000 miles warrenty!

Better to investigate this more closely cause the devil is in the details


Toyota Certified Used Vehicle Warranty

Every Toyota certified used vehicle comes with a 12-month/12,000 mile limited comprehensive warranty starting at the date of purchase. Toyota certified used hybrid vehicles also still receive the 8-year/100,000 mile Factory Hybrid Vehicle Battery Warranty. Toyota certified used vehicles also receive a 7-year/100,000 limited powertrain warranty. Components covered by this warranty include engine components, manual transmission, automatic transmission, axle assembly components and hybrid components.

What in the OP's postings tells you it is a used vehicle?

Why is it not being covered under the 96 months 160km hybrid components warranty? New Vehicle Warranty and Coverage - Toyota Canada

Toyota sells the vehicles for service/use in this climate.

 

Warranty coverage appears to be a real tangle. Rear traction motor is covered under power train. Inverter that powers motor is under hybrid. Cable that connects them? Also warranty exceptions (P16) include water and salt contamination.

 

It would be simple enough to pack the connector and wires with silicone grease. They use that on all the light bulbs. I guess the malfunction light pops up before the resistance gats too high and starts a fire.

 

Not much danger of fire. Inverter package picks up phase imbalance or ground fault and triggers error code. Plan on checking mine next spring and if any signs of corrosion I will be contacting Toyota service. If they don't do anything I will be cleaning it up, flooding with dielectric grease and sealing up.

 

Is silicone grease nonconductive? We are talking here about 400VDC and 100-200 Amps. There is + and minus in that connector

 

Dielectric grease is designed specifically for this type of application. Not DC, three phase AC.