machining debris found in rear axle

Yeah, that’s where my head was at too.

 

Not a mechanic obviously, but the gears looked to me to be pre assembled within a bolt on housing that bolted into the axel. When they replaced my Diff that housing was new so the dealership didn’t pull the ring and pinion. Atleast that’s what I thought.

 

*Im not aware of a known issue (other then these complaints of Toyota recalls for debris left in engines and on axles, etc), not beside the alarming amount of debris that was discovered on service. (A mixture of large, swirling, metal pieces, glitter, and ground metal.) Toyota warranty covers defects, quality, and workmanship.

Thier service department said the only way to know would be to open it up. I kind of don't have a choice as I thought they could just boroscope it.I would have to have them inspect it for a warranty claim.

 

In the sludge I collected and sent with my truck had alot of metal glitter and tiny chips. I collected it on a towel rag and sent with my truck. It took me awhile to clean the mag and collect debris. I am very doubtful that the magnet could hold anything or anymore of what was collected, no telling what's inside until they open it for inspection.

 

If you decide to proceed with inspection I think 95% or more likelihood there will be no issue found and no warranty claim supported. And then you’ll pay for the labor. But, it may help you sleep at night. If you go through with it please let us know the outcome.

 

I will definitely keep you guys posted.

Warranty covers defects and workmanship. Couldn't see a reputable vehicle manufacturer like Toyota saying that is acceptable amount of debris. With all the recalls for the exact same thing in engines and on the rear axles. I would honestly expect them to honor the warranty by cleaning, inspecting, flushing, and/or fixing and repairing if needed.
You wouldn't go to a surgeon and expect to find gauze, dressing, and forceps in a patient and call that a normal procedure. Especially when their own consultants and supervisors say they never saw that much debris come out any differential.

 

You can’t seriously be comparing leaving a surgical tool inside a human being after surgery to there being some machining material on the diff drain magnet. That’s dramatic and absurd.

You’re failing to consider what the definition of an auto defect is. A defect has to either impact the safe operation of the vehicle or impact its value.

Personally I think you’re massively overthinking this and causing yourself completely unneeded stress. The first diff oil change is ALWAYS going to have a ton of glitter, these are not super precise gears and they will have some initial wear.

But — again, if you need to have the diff opened and inspected to sleep at night, be aware that if the dealer finds nothing, they may want you to pay for the labor. Because that means there isn’t an actual defect. Just because you don’t like finding machining debris on the magnet doesn’t mean it’s an actual defect with impact on operation, safety or value. On the other hand, the dealer might do you a solid and do the inspection as a courtesy either way. Entirely depends on the dealer.

 

*ladyboy

The rear diff and axle are manufactured in Thailand.

Hopefully the dealer won't charge you tier-three labor rate for the inspection ($300/hr, usually reserved for hybrid system diagnostics).

 

This debris is completely unacceptable, period. Where I work gears and shafts come back from assembly if they find one piece of shot, from the shot pennig process.

 

That made me laugh too! Let's just hope it is not the dreaded inner-cavity Junior Mint.

 

I dont think it's dramatic or absurd. Especially with thier own recalls are for quality and workmanship. Yes, I compared it to surgery. You wouldn't want FOD in your engine, or in your differential. You wouldn't want a forceps in your open heart or your legs.

 

lol, does Blackstone test for dark chocolate?

 

Update.

Picked up my Tacoma and was told they test drove it, took an oil sample that was sparkly, found more debris on mag, drained it, opened it up, inspected finding more debris, “found no damage to be worried about only normal manufacturing debris” took photos of debris and whatever else. (Wouldn’t get copies so now I must request) and it required to be flushed and filled twice.

I paid $0. I was also told it was courtesy of dealer for being a valued customer. The invoice I received says warranty. Either way Toyota has some serious quality control issues! Further not one qualified maintenance technician would find this acceptable. If this is normal “Manufacturing Debris” Toyota should put out a TSB for owners.

It was also strongly emphasized that I now actively listen to the differential for strange noises, whining, grinding, knocks, bangs, etc. (They must know more of the risks then there admitting) I know that the magnet didn’t suspend everything other then what was pulled out by me (through common knowledge and there own admission)

The push back and downplay is coming from the warranty department not the dealer as they seemed genuine, honest, and willing to help. The warranty department is going to say no noticeable faults or defects no coverage. Don’t be fooled or have your intelligence insulted, quality and workmanship is covered under warranty! Further if something goes wrong in the future it’s documented.

I still don’t think I’m being too dramatic or absurd, I mean it’s just the rear differential of the drivetrain what’s the worst that could happen?


*Turbine Surgeon

 

Did you just pull this out of your butt? What tooling? The drill.

 

Drill bits are in the category of “tooling” and a drill is certainly “machinery”. So I’m not sure what your gripe is. Besides that debris could be from drilling a hole, from tapping a hole, or even from a milling process. If it bothers you to refer to rotary cutting bits of various types as “tooling” then your dispute is with the English language, not Bishop, who is a highly respected member of this forum.

Also, I very much doubt holes and threads are being cut by hand tools, almost certainly done on a bench setup of some kind which one might call…

…”machinery”

 

You spew this garbage out of the blue? Go back to lurking.

 

I am sure the dealership is happy to have done whatever it takes to retain such a valuable client!

 

30,251 miles is not brand new. You mean you bought it brand new in 2023, and now get over 30k miles.

 

Snails!