22TA05 – Axle Shaft May Separate – 2022 Toyota Tundra & Tundra Hybrid

June 23, 2022 NHTSA CAMPAIGN NUMBER: 22V445000

Axle Shaft May Separate

Axle shaft separation can cause a loss of vehicle stability and brake performance, increasing the risk of a crash.

 

NHTSA Campaign Number: 22V445

Manufacturer Toyota Motor Engineering & Manufacturing

Components POWER TRAIN

Potential Number of Units Affected 46,176

 

Summary

Toyota Motor Engineering & Manufacturing (Toyota) is recalling certain 2022 Tundra and Tundra Hybrid vehicles. The flange nuts on the axle shaft sub-assemblies can loosen over time and potentially cause one or both axle shaft sub-assemblies to separate from the axle housing.

 

Remedy

Dealers will inspect the rear axle assembly, tighten the axle flange nuts, and replace any damaged axle-related components if necessary, free of charge. Owner notification letters are expected to be mailed July 15, 2022. Owners may contact Toyota customer service at 1-800-331-4331. Toyota’s number for this recall is 22TA05.

 

Notes

Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.nhtsa.gov.

 

Check if your Vehicle has a Recall

 


2022 Toyota Tundra
2022 Toyota Tundra

 


SAFETY RECALL 22TA05

Certain 2022 Model Year Tundra and Tundra Hybrid Vehicles
Rear Axle Shafts May Separate from Vehicle During Driving
NHTSA Recall No. 22V-445

 

Model / Years Production Period Approximate Total Vehicles Approximate Stop Sale Dealer Inventory
2022 Tundra and Tundra HV Early November 2021 – Mid-June 2022 46,200 500

 

STOP! DO NOT SELL NEW VEHICLES IN DEALER INVENTORY.

Refer to Dealer Inventory Procedures section for more details.

 

On June 23, 2022, Toyota filed a Defect Information Report (DIR) with the National Highway Traffic Safety Administration (NHTSA) informing the agency of our intent to conduct a voluntary Safety Recall on 2022 model year Tundra and Tundra Hybrid vehicles.

 

Condition

Vehicles in this recall have certain nuts on the rear axle assembly that can loosen over time and, in some cases, fall off, potentially causing an axle shaft sub-assembly to separate from the axle. If complete separation occurs, this can affect vehicle stability and brake performance, increasing the risk of a crash.

 

Remedy

For all involved vehicles, Toyota dealers will inspect and retighten the axle flange nuts FREE OF CHARGE. In some cases, axle related components may be replaced FREE OF CHARGE based on inspection results.

 

Covered Vehicles

There are approximately 46,200 vehicles covered by this Safety Recall.  Approximately 300 vehicles involved in this Safety Recall were distributed to Puerto Rico.

 

Owner Letter Mailing Date

Toyota will notify owners by late July 2022.

Toyota makes significant effort to obtain current customer name and address information from each state through industry resources when mailing owner letters. In the event your dealership receives a notice for a vehicle that was sold prior to the Safety Recall announcement, it is the dealership’s responsibility to forward the owner letter to the customer who purchased the vehicle.

Please note that only owners of the covered vehicles will be notified. If you are contacted by an owner who has not yet received a notification, please verify eligibility by confirming through TIS prior to performing repairs. Dealers should perform the repair as outlined in the Technical Instructions found on TIS.

 

New Vehicles in Dealership Inventory

There are approximately 500 vehicles in new dealer inventory as of June 21, 2022.

 

Inspection Reminder Mirror Hang Tags for Covered Vehicles in New Dealer Stock

To easily recognize vehicles involved in this Safety Recall, each dealership should utilize Inspection Reminder Hang Tags. Inside the vehicle’s glove box are stickers containing the VIN. Apply one of these stickers to the hang tag and install the hang tag in the vehicle. A sample copy of the Inspection Reminder Hang Tag has been included for your reference.

 

Pre-Owned Vehicles in Dealer Inventory

To ensure customer satisfaction, Toyota requests that dealers complete this Safety Recall on any used vehicles currently in dealer inventory that are covered by this Safety Recall prior to customer delivery. However, if the campaign cannot be completed (for example, due to remedy parts availability), delivery of a covered vehicle is acceptable if disclosed to the customer that the vehicle is involved in a Safety Recall.

Toyota expects dealers to use the attached Customer Contact and Vehicle Disclosure Form to obtain vehicle buyer information. Dealers are expected to provide a copy of the completed form, along with the most current FAQ, to the vehicle buyer. Toyota and the dealer may use this information to contact the customer when the remedy becomes available.

 

Toyota Certified Used Vehicle (TCUV)

The TCUV policy prohibits the certification of any vehicle with an outstanding Safety Recall, Special Service Campaign, or Limited Service Campaign. Thus, no affected units are to be designated, sold, or delivered as a TCUV until all applicable Safety Recalls, Special Service Campaigns, and Limited Service Campaigns have been completed on that vehicle.

 

Toyota Rent-A-Car (TRAC) & Service Loaners

Toyota requests that dealers remove all TRAC and Service Loaner vehicles from service that are covered by a Safety Recall unless the defect has been remedied.

 

Customer Contacts

Customers who receive the owner letter may contact your dealership with questions regarding the letter and/or the Safety Recall. Please welcome them to your dealership and answer any questions that they may have. A Q&A is provided to assure a consistent message is communicated.

Customers with additional questions or concerns are asked to please contact the Toyota Brand Engagement Center (1-888-270-9371) – Monday through Friday, 8:00 am to 8:00 pm, Saturday 9:00 am to 7:00 pm Eastern Time.

 

Salvage Title Vehicles

Every attempt should be made to complete an open Safety Recall when circumstances permit, unless noted otherwise in the Safety Recall dealer letter.

For complete details on this policy, refer to Toyota Warranty Policy 4.17, “What Is Not Covered by The Toyota New Vehicle Limited Warranty”.

 

Media Contacts

It is imperative that all media contacts (local and national) receive a consistent message. In this regard, all media contacts must be directed to Tyler Litchenberger (469) 292-2671 in Toyota Corporate Communications. Please do not provide this number to customers. Please provide this contact only to media.

 

Remedy Procedures

Refer to TIS for Technical Instructions on repair. Conduct all non-completed Safety Recalls and Service Campaigns on the vehicle during the time of appointment.

 

Repair Quality Confirmation

The repair quality of covered vehicles is extremely important to Toyota. To help ensure that all vehicles have the repair performed correctly, please designate at least one associate (someone other than the individual who performed the repair) to verify the repair quality of every vehicle prior to customer delivery.

 


Frequently Asked Questions

Original Publication Date: June 24, 2022

 

Q1: What is the condition?

Vehicles in this recall have certain nuts on the rear axle assembly that can loosen over time and, in some cases, fall off, potentially causing an axle shaft sub-assembly to separate from the axle. If complete separation occurs, this can affect vehicle stability and brake performance, increasing the risk of a crash.

 

Q1a: Are there any symptoms/warnings that the condition exists?

If you notice an oil leak by either rear tire, vibration, and/or abnormal noise, the vehicle may be experiencing symptoms related to this Safety Recall.

 

Q2: What is Toyota going to do?

Toyota will send an owner notification by first class mail by late July 2022, advising owners to make an appointment with their authorized Toyota dealer to have them inspect and retighten the axle flange nuts FREE OF CHARGE. In some cases, axle-related components may be replaced FREE OF CHARGE based on the results of the inspection.

 

Q3: Which and how many vehicles are covered by this Safety Recall?

There are approximately 46,200 vehicles covered by this Safety Recall.

Model Name Model Year Production Period
Tundra and Tundra Hybrid 2022 Early November 2021 – Mid-June 2022

 

Q4: How long will the remedy take?

The remedy takes approximately 50 minutes. However, depending upon the inspection results and dealer’s work schedule, it may be necessary to make the vehicle available for a longer period of time.

 

Q5: How does Toyota obtain my mailing information?

Toyota uses an industry provider who works with each state’s Department of Motor Vehicles (DMV) to receive registration or title information, based upon the DMV records. Please make sure your registration or title information is correct.

 

Q6: What if I have additional questions or concerns?

If you have additional questions or concerns, please contact the Toyota Brand Engagement Center at 1-888-270-9371 Monday through Friday, 8:00 am to 8:00 pm, Saturday 9:00 am to 7:00 pm Eastern Time.

 


TECHNICAL INSTRUCTIONS

Rear Axle Shafts May Separate From Vehicle During Driving – 2022 Toyota Tundra & Tundra Hybrid

 

Rear Axle Shafts May Separate From Vehicle During Driving – 2022 Toyota Tundra & Tundra Hybrid

 


Description of Problem:

The subject vehicles are equipped with a rear axle assembly, consisting of an axle housing, axle shaft sub-assemblies, and a differential carrier assembly.  Each axle shaft sub-assembly is secured to the axle housing using studs and flange nuts.  The flange nuts can loosen over time and, in some cases, fall off, potentially causing one or both axle shaft sub-assemblies to begin to separate from the axle housing.  If the vehicle is operated with loosened nuts, the operator may experience vibration, hear an abnormal noise, and/or observe leaking of differential oil.  If an axle shaft sub-assembly completely separates, this can affect vehicle stability and brake performance, increasing the risk of a crash.

 

Chronology of Principal Events:

 

March 2022 –June 2022

In mid-March 2022, Toyota received a field report on a MY2022 Toyota Tundra indicating that the flange nuts connecting the axle shaft sub-assembly to the axle housing were missing, from their securing studs and there was complete separation between the axle shaft sub-assembly and axle housing along with damage to the surrounding parts.  Toyota began to investigate this incident and recovered the related parts.

 

In late March, the parts that were recovered from the vehicle in the initial field report were sent to the supplier for further inspection.  Additionally, a second field report was received with a similar condition.  The parts from this vehicle were recovered and also sent to the supplier for evaluation.  In both cases, it was observed that the flange nuts were missing from the studs, and there was complete separation between the axle shaft sub-assembly and the axle housing.  However, what may have caused the nuts to loosen and become missing was unknown.  The parts were then sent to Toyota’s design group for evaluation.

 

Toyota began a 100% torque check at Toyota’s vehicle assembly facility for all vehicles.  This activity indicated that all nuts were tightened to the design specification prior to leaving the production facility.  Additionally, Toyota began conducting a field survey to understand the torque values of vehicles in the field.  Toyota and the supplier continued to investigate all of the parts and components related to the rear axle and rear differential to check if the individual components were within their design specification; no out-of-specification condition was found.

 

In April, Toyota had received an additional report with a partial separation between the axle shaft sub-assembly and the axle housing (i.e., two flange nuts were missing and two were loose).  The field surveys indicated that vehicles in the field had flange nuts with torque values that were lower than the design specification.  It was hypothesized that a reduction of the axial force in the joint was occurring.  In mid-April an increased torque for the flange nuts was implemented at the supplier and additional torque checks were also done for parts at the assembly plant.

 

In early May, vehicle drive testing was undertaken using rear axles with the increased torque specification.  After the testing, the axial force in the joint was found to have reduced and there was a reduction in torque values on the flange nuts.  At this point it was believed that the process for pressing the studs onto the axle shaft sub-assemblies had unknown variations.

Further investigation of parts variations revealed two causes: (1) lack of adequate press force exerted on some of the studs, and (2) greater than expected serration resistance.  Both causes combined contributed over time to the loss of joint integrity between the axle shaft sub-assembly and the axle housing.  Subsequently, changes were made in the stud pressing process, and studs were introduced to the assembly process on a lot-by-lot basis to minimize the variation related to the stud head height in the pressing process.  In early June, an increased torque specification was implemented to account for any inadequacy in axial force that might result in flange nut loosening.

 

Based on the investigation results and Toyota’s engineering judgement, it was determined that, if the flange nuts loosen and, in some cases, fall off, this can cause one or both axle shaft sub-assemblies to begin to separate from the axle housing.  If the vehicle is operated with loosened nuts, the operator may experience vibration, hear an abnormal noise, and/or observe leaking of differential oil.  If an axle shaft sub-assembly completely separates, this can affect vehicle stability and brake performance, increasing the risk of a crash.

 

June 17, 2022

Toyota decided to conduct a voluntary safety recall campaign.

As of June 9, 2022, based on a diligent review of records, Toyota’s best engineering judgement is there are 5 Toyota Field Technical Reports (received between March 17, 2022 and June 9, 2022) and 5 warranty claims that have been received from U.S. sources that relate or may relate to this condition which were considered in the decision to submit this report.

 

Description of Corrective Repair Action:

All known owners of the subject vehicles will be notified to return their vehicles to a Toyota dealer.  For all involved vehicles, the dealers will inspect the rear axle assembly and retighten the axle flange nuts.  For any vehicles where other axle-related components are damaged, they will be replaced, if necessary.

 

Reimbursement Plan for pre-notification remedies

As the owner notification letters will be mailed out well within the active period of the Toyota New Vehicle Limited Warranty (“Warranty”), all involved vehicle owners for this recall would have been provided a repair at no cost under the warranty.

 

Recall Schedule:

Notifications to owners of the affected vehicles will occur by late July 2022.  A copy of the draft owner notification will be submitted as soon as it is available.

 


2 Affected Products

Vehicles

MAKE MODEL YEAR
TOYOTA TUNDRA 2022
TOYOTA TUNDRA HYBRID 2022

 


6 Associated Documents

Toyota – DEFECT INFORMATION REPORT – June 2022

RMISC-22V445-9253.pdf 61.231KB

RMISC-22V445-9253

 


Recall Acknowledgement

RCAK-22V445-9747.pdf 645.844KB

RCAK-22V445-9747

 


Defect Notice 573 Report

RCLRPT-22V445-7572.PDF 215.751KB

RCLRPT-22V445-7572

 


Remedy Instructions and TSB

RCRIT-22V445-6548.pdf 2436.794KB

RCRIT-22V445-6548

 


Remedy Instructions and TSB

RCRIT-22V445-1175.pdf 2344.173KB

RCRIT-22V445-1175

 


Toyota – Dealer Letter – June 2022

RCMN-22V445-1685.pdf 519.902KB

RCMN-22V445-1685

 


Latest Recalls Documents

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=22V445&docType=RCL

 


 

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