Failed Transfer Case. 2009 Toyota RAV4

robdrum

I purchased a used 2009 RAV4 with about 78,000 miles. It was a one owner with a clean car fax. It was great during the test drive. About 2 days after I purchased it, it started to make a rattle/rumble/vibration at approximately 40mph and 1500 - 1800rpm. It seems like the noise was coming from the transaxle/transmission area. The noise progressively got worse. It typically happened when on an incline. I took it into a dealer and they flashed the ECU since there were multiple TSBs out with this problem related the ECU. This helped with the problem for a week. Then the rumble came back with a vengeance. The dealer worked on diagnosing for a couple of days. The Toyota engineers on the technical service line had the dealer's technician taking heat shields, plastic covers off, etc thinking something was just hitting resonate frequency and vibrating loudly. Nothing helped. Eventually the technician used listening ears and isolated the noise to the transfer case. The official diagnosis was components in the transfer case were failing. Replacing the transfer case is a $4,200 repair. I know replacing fluid to fix a mechanical issue doesn't typically work. The dealer recommended not replacing the fluid and just driving it until it completely failed if I wasn't going to replace the transfer case right away. Has anyone had success changing fluid for a similar problem?

I bought this vehicle thinking Toyota still were high quality. I've discovered RAV4s are basically tin cans on wheels. It makes an amazing amount of creaks and rattles. When spoke to the Toyota customer service representative on the phone I was informed Toyotas are basically designed to go the 60,000 miles (the manufacturer warranty). After that it's anyone's guess how long the mechanical components will last. Should have gone with a Ford or Chevy.

junebug1701

You bought a used vehicle with 78,000 miles on it. You have no idea what the previous owner(s) did to it. They may have been using it to tow a big boat or travel trailer. Was the oil in the transfer case or differential ever changed? If you had bought the thing new, I could understand your complaint, but don't badmouth a particular brand's quality only from judging one used example. You may have had bigger problems with a used Ford or Chevy with 78,000 miles. I bought my 2008 RAV4 new and have had all scheduled maintenance done at my dealer with the exception of changing the brake pads which I did myself. Even though I bought the Toyota 8 year extended warranty for $659, I haven't needed to use it yet and still have 2 years to go.