NHTSA Complaint #10630560 — 2009 TOYOTA RAV4

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. 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 I SPOKE TO THE TOYOTA CUSTOMER SERVICE REPRESENTATIVE ON THE PHONE I WAS BASICALLY INFORMED TOYOTAS ARE NOW DESIGNED TO GO THE 60,000 MILES (THE MANUFACTURER WARRANTY). AFTER THAT IT'S ANYONE'S GUESS HOW LONG THE MECHANICAL COMPONENTS WILL LAST. *TR