NHTSA Complaint #11207128 — 2011 TOYOTA SIENNA

THIS VEHICLE HAS ALL WHEEL DRIVE AND USES AN ELECTROMECHANICAL COUPLER ON THE REAR DIFFERENTIAL. IT IS VERY SIMILAR CONFIGURATION TO THE TOYOTA RAV4 THAT USES A VISCOUS COUPLER IN THE SAME LOCATION. MY COUPLER HAS FAILED DUE TO THE FRONT BEARING FAILING. THE VEHICLE IS 8 YEARS OLD AND HAS ABOUT 95000 MILES ON IT. TOYOTA HAS ISSUED A TECHNICAL SERVICE BULLETIN AND PROVIDED EXTENDED WARRANTY COVERAGE FOR THE BEARING FAILURE PROBLEM ON THE RAV4. SO FAR, THEY HAVE REFUSED TO PROVIDE SIMILAR COVERAGE FOR REPAIRS ON THE AWD SIENNA, EVEN THOUGH THE FAILURE MODE IS IDENTICAL. WE FIRST NOTICED THE PROBLEM WHEN THE VEHICLE STARTED MAKING LOUD GRINDING NOISE FROM THE REAR AXLE WHILE DRIVING. IT WASN'T CLEAR WHAT THE SOURCE OF NOISE WAS, BUT AFTER FINDING THE SERVICE BULLETIN FOR THE PROBLEM ON THE RAV4, IT BECAME CLEAR THIS SAME BEARING FAILURE WAS HAPPENING ON THE AWD SIENNA'S, SO IT WAS REPAIRED. IT WAS REPAIRED BEFORE IT FAILED CATASTROPHICALLY. IT IS HARD TO KNOW WHAT WOULD HAVE HAPPENED IF THE SOUND WAS IGNORED. WOULD THE DRIVE SHAFT SIEZE UP? ENGINE STALL? TRANSMISSION FAIL? TOYOTA DOES NOT SELL THIS BEARING FOR THE SIENNA, THEY REQUIRE THE ENTIRE COUPLING TO BE REPLACED, WITH A LIST PRICE OVER $1700, PLUS LABOR. THIS DEFECTIVE PART SHOULD BE SUBJECT OF A RECALL AND THE REPAIR PERFORMED ON ALL AWD SIENNA WITH THE DEFECTIVE BEARING CONFIGURATION.