Final Warranty Inspection UPDATE

Just got back from my Final Warranty Inspection and am I ever glad I had it done.

2021 SR5 4x4 Auto, 36000Km.

Last service I advised the Dealer I was having problem with engaging and disengaging the 4x4. They inspected it and said all good.

Took Service Mgr out for a ride today to show him the problem and when the inspection was done I now need a new Front & Rear diff. They found metal pieces in the Rear Dif.

 

HMMM, I highly doubt front and rear diffs both pooped the bed. I'd guess more like a front diff or transfer case actuator.
It's good they recognize the problem and are making an attempt to remedy, but it sounds like their service numbers are down, or their parts-cannon is much larger than most.

 

Wait, wasn’t there just a recall for this exact same thing?

 

Sorry to hear you had to have this/these problems, but good for you that you stuck to your guns and said 'Hey... Something isn't right here!' and got it caught under the wire.
When my truck was new/newer, I religiously went in every 5K miles for the freebie 'once over'. Good thing I did. At 15K miles the dealer found a leaky rear axle seal. They replaced the seal, Wheel bearing (Just in case) and new brake shoes on the one side, and topped off the differential oil.
I was making trips between WA. ST and AZ. at the time and all I could think of was 'At least I didn't seize up in the middle of 'No-Where-Your'e-Going-To-Die-Here-And-Eaten-By-Coyotes' Nevada... LOL

 

Dealer gave me a copy of what's to be done. No sure exactly what it all means. All I know the Service Advisor told me they had to replace Front & Rear Diff. They are Back Ordered until end of April if I'm lucky.

 

Well here's where I am so far.
They have changed Front and Rear Diff Carrier Subassembly. During testing the Mech stated the need to replace the Transfer Case due to hesitation from 3rd to 4th.
Picked up Truck last Thursday and on the way home tried to engage 4hi on a back road driving under 60kph and would not engage. After following Owners Manual trouble shooting it finally engaged. When changing from 4hi to 2wd the same shudder and bang happened again.
Back to the Dealer Friday morning as the Transfer Case was going to be replaced Today (Monday).
I called today for an update and they have found the problem and should be fixed tomorrow (Hopefully)

 

Well here's where I am so far.
They have changed Front and Rear Diff Carrier Subassembly. During testing the Mech stated the need to replace the Transfer Case due to hesitation from 3rd to 4th.
Picked up Truck last Thursday and on the way home tried to engage 4hi on a back road driving under 60kph and would not engage. After following Owners Manual trouble shooting it finally engaged. When changing from 4hi to 2wd the same shudder and bang happened again.
Back to the Dealer Friday morning as the Transfer Case was going to be replaced Today (Monday).
I called today for an update and they have found the problem and should be fixed tomorrow (Hopefully)

 

I could use some input.
After New Transfer Case, Front and Rear diff replaced, the original problem still there. 2 wd to 4wd not engaging properly or when it finally does a loud bang and shutter from 4wd to 2wd. Dealer has blamed it on Tires. I have a SR5, original tires 245/75/16 I replaced them with TRD OR rims and stock tires (GR Wrangler) 265/70/16. They removed the tires from my truck and took four from Tacoma they had on the lot 245/75/16 and that fix the problem so they're blaming it on the tires. How is this possible? Any input would be greatly appreciated.
I called 3 other dealer in my area and they all stated that switching 245 for 265 will not cause any problems.

I'm glad I still have the balance of the 2 yrs on the 5yr / 100000km powertrain or should I start considering trading it in?

 

Yes, but did -you- drive it with the stock tires/wheels and verify that the problem went away? ( i.e. - Show me!)

Maybe Toyota told the Dealer no more more free $$. Did he mod his truck? Yes? Take the mod off, tell him prob went away, put mod back on. Claim denied.

I’ve got 4R wheels and 265/70/17 tires on my SR. No issues. Just doesn’t add up that it’s the tires.

 

I second this scenario. Verify yourself dealers like to shape shift there way out of things when it gets this far down the line. Makes them look bad also hurts their numbers

 

Sounds like the dealer wanted to milk Toyota for some money by throwing parts at something they should have known wouldn’t fix your complaint.

 

I did test drive it with the Mechanic for about 20 min and everything worked like it should. 2wd to 4wd and back 20 times at least with no issues.

I know something doesn't add up. They removed my 265's tires and installed Hankook AT 245's and that is what I get

 

Dealer gets warranty parts from Toyota with no money changing hands. Toyota pays 50 cents on the dollar for labor. Replacing diffs after seeing metal debris in the fluid is reasonable action. No milking here.

T-SB-0045-23 (NHTSA copy) installs foam pads inside the cab corners and mass damper cups in under the rear cab mount bushings: https://www.tacomaworld.com/posts/17791543 It doesn't touch the drivetrain.