Rear Differential Completely Destroyed at 25,000 kilometers.

The only way 4wd would matter is if he had the rear in a bind with the front and the rear lost..... which is unlikely.

Most likely something failed allowing the gears to bind or something was wrong with the material in the ring/pinion.

 

I honestly don't know about what kind of gears are in these trucks, but are the cast or forged?

 

I agree with this. Have seen it personally myself with these "mechanics". If possible @2016LimitedTaco , get the shop foreman to inspect the tech's work and get him to confirm the install and set the proper tolerances with the tech, which "should" be better than factory production tolerances. Hopefully they have enough experienced techs there to work on your truck. There are things that some techs don't do well and a warranty issue like this that can fail in a catastrophic way is a liability issue for all parties repairing the vehicle.
I've worked next to techs who took a f@cking ROLOC bristle wheel to an aluminum cylinder block to clean head gasket residue when a razor blade would have sufficed and not actually remove material !! This is after the head got sent out and decked for warpage due to an overheating issue. This was at a dealer I worked at. It's scary what kinda nonsense gets passed. Hopefully your diff issues get resolved properly.


This is a ROLOC wheel for air angle grinder for those who don't know what I'm talking about. This left depressions and gouges in the "supposedly" super flat aluminum surface the cylinder head should be for the gasket to seat and load properly.

 

I honestly don't know either my guess would be that they are forged. If these were left as just a cast they would only be about 66% as strong as they would be as a forged item, which basically means that they were cast into a mold or as an ingot and then mechanically hardened. But with that process there has to be a heat treatment. I tend to refer to anything forged as cast. Simply because forging is the process that takes place after the casting. The difference would be extruded bar used for Machining camshafts, which is also still a casting that has had some other process performed. I'll elaborate on that. When you have an extruded piece you started off with a casting that has been forged you'll then take that forging and heat it up and squirt it through something or squeeze it through something which would then stretch out and lengthen the grain boundaries in the steel making it stronger. The odds that our gear sets where machined out of an extruded Billet? Talk about cost-prohibitive.

 

Thanks for sharing. As one of the mods put it, shit happens... it's a machine. It certainly doesn't help the 3rd gen reputation, lol...but nonetheless. Toyota will fix it under warranty. Good luck.

 

I like your idea and will definitely try to do this diplomatically. They always get pissed when you question their ability or procedures but I know how these shops work. Peace meal work and a certain time line. If you want to take your time and get it right you're probably going to get shit on for not moving fast enough.

 

Check for loose Ring bolts that could have backed out and jammed up the gears?

 

The tech may have said replacing individual parts in the diff but I would be really surprised if they didn't just put a whole new 3rd member in there. It's just as much, if not less, of a labor cost and they come pre assembled from the factory.

Also, I hope you have called toyota corporate and explained your frustration, loss of trust in the truck and absolute dismay at the fact that you aren't being given a loaner. They will open a case and maintain contact with your dealer as well. While I agree the 3rd gen has some ridiculous issues for a new vehicle, Toyota has actually been decent in the customer relations department (for me at least). It's worth a try.

 

That sucks. Here in the US they'll usually replace the entire 3rd member. Its generally cheaper in the long run. Sounds like Canadian warranties suck ass. Not even a rental. Your dealership acts like it's coming out of their pocket.

 

I agree about his dealership, very surprised they would question him. It doesn't have to do with Toyota Canada tho. I just mentioned to my service advisor that my diff was howling when it went in for 16,000km service (wasn't even too concerned about it) and they ordered and replaced the third member the following week.

 

OP needs to take his truck to your dealer

 

That's awesome that they changed it out for you, I was talking to the Salesman at my Dealership and he said they just changed out a rear in one of the Tacoma's he sold.

 

Mine was diagnosed. By that I mean in writing as "Founded" significant driveline noise. Yet not fixed due to corporate not having a fix for what they consider normal. Lost a lot of respect for Toyota.

 

So are the replacing problematic differential with another of the same ?

 

No fix. Escalated to corporate and told they will not fix my truck. I am stuck with it. Also stuck with the pulsating brakes they refuse to fix because it's "normal"

 

WOW

 

It's always "normal" till there's a fatality or two involved.

 

I will be on it tomorrow but the sale guy I had is now at another dealership (Lexus) and is going to see what he can do. I think I will open a ticket with corporate just so there's a history there.

 

Good call Derek