NHTSA Complaint #10564668 — 2006 TOYOTA RAV4

OUR 2006 RAV4 CREATES A GROWLING SOUND FROM THE REAR DIFFERENTIAL AREA WHEN DRIVING AT 35 TO 40 MPH. THE SOUND GOES AWAY WHEN ACCELERATING ABOVE 40 MPH. THE NOISE IS BECOMING MORE PRONOUNCED WITH TIME. TWICE THE VEHICLE WAS TAKEN TO A TOYOTA DEALERSHIP AND THEY WERE UNABLE TO IDENTIFY THE CAUSE. RESEARCH ONLINE LOCATED TECHNICAL SERVICE BULLETIN TSB-0080-13 WHICH DISCUSSES SYMPTOMS VERY SIMILAR TO WHAT OUR RAV IS EXPERIENCING. A CALL TO THE TOYOTA DEALERSHIP RESULTED IN BEING INFORMED THAT DETERIORATION OF THE REAR DIFFERENTIAL COUPLING DUE TO CONTAMINATED BEARING COULD BE THE PROBLEM, AND THAT ESTIMATED COST OF REPAIR COST IS $1,925. I ASKED IF FAILURE OF THE COUPLING COULD BE CATASTROPHIC, CAUSING LOSS OF CONTROL. THE ANSWER WAS NOT LIKELY UNLESS DRIVING ON SLIPPERY SURFACES. THIS VEHICLE IS REGULARLY MAINTAINED, AND HAS NOT BEEN IN AN ACCIDENT. IT IS DISAPPOINTING THAT WE ARE LOOKING AT AN IMPENDING FAILURE OF THE DRIVETRAIN. IS THIS A FLAW IN THE ENGINEERING/DESIGN THAT WENT INTO THIS VEHICLE? WHAT ELSE CAN BE DONE BEYOND INFORMING OTHERS IN THE INTEREST OF THEIR PERSONAL SAFETY? *TR