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

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

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

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TECHNICAL INSTRUCTIONS FOR SAFETY RECALL 22TA05 REAR AXLE SHAFTS MAY SEPARATE FROM VEHICLE DURING DRIVING (INSPECTION + REPAIR) CERTAIN 2022 MODEL YEAR TUNDRA AND TUNDRA HV Update • 10-13-22 – Added repair process for vehicles that fail inspection • 7-21-22 – Video overview added to clarify inspection process • 6-28-22 – TI updated to include inspection website URL The repair quality of covered vehicles is extremely important to Toyota. All dealership technicians performing this recall are required to successfully complete the most current version of the E-Learning course “Safety Recall and Service Campaign Essentials”. To ensure that all vehicles have the repair performed correctly; technicians performing this repair are required to currently have completed all of the following courses: – T351 Toyota Drivetrain Service and Repair It is the dealership’s responsibility to select technicians that have completed the above courses to perform this repair. Carefully review your resources, the technician skill level, and ability before assigning technicians to this repair. It is important to consider technician days off and vacation schedules to ensure there are properly trained technicians available to perform this repair at all times. 2 I. OPERATION FLOW CHART Are 1 or more nuts missing from the LEFT (driver side) axle flange? Covered No further action required Not ..Covered.. Document condition with photos and upload to website Yes Campaign completed, return the vehicle to the customer Verify Vehicle Eligibility 1. Confirm VIN matches the RO. 2. Check TIS Vehicle Inquiry or Service Lane Vehicle One-View for Campaign eligibility. Are ALL 4 nuts under 20 Nm on the LEFT (driver side) axle flange? Are ALL 4 nuts under 20 Nm on the RIGHT (passenger side) axle flange? No No Are 1 or more nuts missing from the RIGHT (passenger side) axle flange? Yes Document condition with photos and upload to website Yes No Torque all 4 nuts on the RIGHT side to 95 Nm and photograph Yes No Are 1 or more nuts missing from the RIGHT (passenger side) axle flange? Document condition with photos and upload to website Are ALL 4 nuts under 20 Nm on the RIGHT (driver side) axle flange? Torque the 4 nuts on the RIGHT side to 95 Nm and photograph No Yes No Yes Replace axle components on the side(s) that failed inspection Torque the 4 nuts on the LEFT side to 95 Nm and photograph Test drive at least two miles at highway speed Re-torque all four nuts on the side(s) that had axle components replaced 3 II. IDENTIFICATION OF AFFECTED VEHICLES 1. CHECK VEHICLE FOR CAMPAIGN ELIGIBILITY a. Compare the VIN on the vehicle to the VIN on the Repair Order to ensure they match. b. Check TIS Vehicle Inquiry or Service Lane Vehicle One-View to confirm the VIN is involved in this Campaign, and that it has not already been completed. Note: TMNA warranty will not reimburse dealers for repairs completed on vehicles that are not affected or were previously completed, even by another dealer. III. PREPARATION A. PARTS NOTE: PARTS ONLY REQUIRED IF VEHICLE FAILS INSPECTION. DO NOT ORDER PARTS BEFORE INSPECTION IS COMPLETE. Category Part Number Part Description Quantity Only order/replace parts on the side(s) that failed inspection. A photo of missing or under torqued nuts will be required. LEFT (Driver) Side 90468-A0007 Clip (For Brake Tube)* 1 47804-60011 Cover Sub-Assy, Disc Brake Dust, Rear LH 1 42460-0C020 Hub & Bearing Assy, Rear Axle, LH 1 90208-A0001 Washer (For Rear Axle Shaft)* 1 42423-34040 Retainer, Rear Axle Bearing Inner* 1 90520-46014 Ring, Snap (For Rear Axle Shaft)* 1 90310-A0004 Seal, Oil (For Rear Axle Shaft)* 1 90301-A0015 Ring, O (For Rear Axle Bearing)* 1 90114-A0004 Bolt, Serration* 4 90178-A0057 Nut, Flange* 4 94622-41200 Washer, Plate* 4 RIGHT (Passenger) Side 90468-A0007 Clip (For Brake Tube)* 1 47803-60011 Cover Sub-Assy, Disc Brake Dust, Rear RH 1 42450-0C030 Hub & Bearing Assy, Rear Axle, RH 1 90208-A0001 Washer (For Rear Axle Shaft)* 1 42423-34040 Retainer, Rear Axle Bearing Inner* 1 90520-46014 Ring, Snap (For Rear Axle Shaft)* 1 90310-A0004 Seal, Oil (For Rear Axle Shaft)* 1 90301-A0015 Ring, O (For Rear Axle Bearing)* 1 90114-A0004 Bolt, Serration* 4 90178-A0057 Nut, Flange* 4 94622-41200 Washer, Plate* 4 MISCELLANEOUS (Required for one or both sides) 00475-1BF03 Brake Fluid (DOT 3 or 4) 2 08885-02506 Toyota Genuine Differential gear oil LT SAE 75W-85 APL GL-5 or equivalent 2 12157-10010 Gasket (For Rear Axle Housing Filler Plug) 1 *Same part number used for both sides 4 B. TOOLS & EQUIPMENT • Standard Hand Tools • Torque Wrench • Smart Phone or Camera • Fine tip paint marker • Hydraulic Press • Cut-Off Wheel SST – These Special Service Tools will be required for this repair: Part Number Tool Name Drawer # Quantity 09308-00010* Oil Seal Puller* 3 1 09521-25011* or 09521-25012 Rear Axle Shaft Puller* 7 1 09521-60020** Rear Axle Tool** N/A 1 09631-12090* Seal Ring Tool* 3 1 09726-40010 (or equivalent) Lower Control Shaft Bearing Replacer N/A 1 09951-01100* Replacer 110* 11 1 09951-00770* Replacer 77* 11 1 09951-07150* Handle Assembly 150 – 6.25 Inch* 12 1 *Essential Tool **Available through Loaner Tool Program. Do NOT order loaner tools until all parts are received. IV. WORK PROCEDURE TABLE OF CONTENTS COMPONENTS ························································································································· V LEFT REAR AXLE HOUSING FLANGE NUT INSPECTION·····························································VI RIGHT REAR AXLE HOUSING FLANGE NUT INSPECTION ························································· VII AXLE SHAFT COMPONENT REPLACEMENT* ············································································ VIII ADD DIFFERENTIAL OIL* ·········································································································· IX REINSTALL BRAKE HARDWARE AND WHEELS* ·········································································· X TEST DRIVE AND RE-TORQUE* ································································································ XI REINSTALL BRAKE HARDWARE AND WHEELS ········································································· XII *ONLY required for vehicles that fail inspection 5 V. COMPONENTS The image below is for the left (driver) side. Reference this image for the right (passenger) side as well. PART NAME 1 CLIP (FOR BRAKE TUBE) 2 COVER SUB-ASSY, DISC BRAKE DUST, REAR 3 HUB & BEARING ASSY, REAR AXLE 4 WASHER (FOR REAR AXLE SHAFT) 5 RETAINER, REAR AXLE BEARING INNER 6 RING, SNAP (FOR REAR AXLE SHAFT) 7 SEAL, OIL (FOR REAR AXLE SHAFT) 8 RING, O (FOR REAR AXLE BEARING) 9 BOLT, SERRATION 10 NUT, FLANGE 11 WASHER, PLATE 1 2 3 4 5 6 7 8 9 10 11 6 VI. LEFT REAR AXLE HOUSING FLANGE NUT INSPECTION 1. WATCH INSPECTION VIDEO OVERVIEW a. Click the link to the left to watch a video overview of the inspection and photo upload process. Remedy Inspection Website https://22ta05.imagespm.info/ 2. LOG INTO REMEDY INSPECTION WEBSITE a. Navigate to the URL shown the left on a computer, or for a more seamless photo upload process, scan the QR code with your smartphone. b. Log in to the website. Username: 5-digit Dealer Code Default Password: xxxxx NOTE: Each dealer only has a single account, please ensure that the reset password is communicated to all technicians and dealer associates that will be utilizing this website. c. Enter all requested information along with VIN. d. Follow along on the website as you go through the procedure and upload images as requested. 3. CHECK FOR MISSING AXLE SHAFT FLANGE NUTS a. Release the parking brake. b. Lift the vehicle. c. Remove the left (driver) rear tire. d. Check to see if all 4 nuts are present on the axle housing flange. If one or more nuts are missing, this side has failed inspection. 7 Upload photo to website as prompted then proceed to section VII. RIGHT REAR AXLE HOUSING FLANGE NUT INSPECTION Yes No Is there at least one nut missing on the LEFT (Driver) Side? Proceed to step 4 Example of missing nut 8 4. MATCHMARK NUTS ON LEFT SIDE a. Using a fine tip paint marker, matchmark all 4 nuts, washers, and the axle housing flange. b. Mark “D” for “Driver” close to the axle shaft flange so it will be visible while taking photos of the nuts/studs. 5. TEMPORARILY REMOVE BRAKE LINE HARDWARE TO ALLOW ACCESS TO UPPER LEFT NUT a. Remove the outermost bolt that secures the hard brake line to the axle housing. NOTE: Some parts removed for visibility 6. TORQUE STEP 1: CHECK TO SEE IF ALL FOUR (4) NUTS ON LEFT SIDE MOVE AT 20 Nm a. Set torque wrench to 20 Nm (204 kgf cm, 177 in. lbf) b. Tighten each nut to 20 Nm (204 kgf cm, 177 in. lbf) following the tightening sequence shown in the image to the left. • Only move the brake line enough to create clearance for a torque wrench. Excessive movement could result in permanent damage to the brake line or loosing of the joint. • Be careful not to scratch or cause other damage to the brake line. • Do NOT use extensions with the torque wrench. c. Check the matchmarks to see if the nuts moved. If ALL FOUR (4) moved, this side has failed inspection. Front of Vehicle 9 Upload photos to website as prompted then proceed to section VII. RIGHT REAR AXLE HOUSING FLANGE NUT INSPECTION Yes No Did ALL FOUR nuts move on the LEFT (Driver) Side when torqued to 20 Nm? Proceed to step 7 NOTE: Some parts removed for visibility 7. TORQUE STEP 2: INCREASE TORQUE TO 95 Nm a. Set torque wrench to 95 Nm (969 kgf cm, 70 ft. lbf) b. Tighten each nut to 95 Nm (969 kgf cm, 70 ft. lbf) following the tightening sequence shown to the left. • Only move the brake line enough to create clearance for a torque wrench. Excessive movement could result in permanent damage to the brake line or loosing of the joint. • Be careful not to scratch or cause other damage to the brake line. • Torque nuts to 95 Nm (969 kgf cm, 70 ft. lbf). DO NOT use torque specification listed in Repair Manual. • When torquing the nut apply torque in a smooth slow rotation. DO NOT quickly apply torque. • Do NOT use extensions with the torque wrench. Front of Vehicle 10 c. Photograph the matchmark positions post-torque and upload 2 photos to website (front and rear of axle; 2 nuts per photo). Example: Front of Left Side Example: Rear of Left Side 11 VII. RIGHT REAR AXLE HOUSING FLANGE NUT INSPECTION 1. CHECK FOR MISSING AXLE SHAFT FLANGE NUTS a. Remove the right (passenger) rear tire. b. Check to see if all 4 nuts are present on the axle housing flange. If one or more nuts are missing, this side has failed inspection. Example of missing nut 12 Upload photo to website as prompted then proceed to section VIII. AXLE SHAFT COMPONENT REPLACEMENT Yes No Is there at least one nut missing on the RIGHT (Passenger) Side? Proceed to step 2 2. MATCHMARK NUTS ON RIGHT SIDE a. Using a fine tip paint marker, matchmark all 4 nuts, washers, and the axle housing flange. b. Mark “P” for “Passenger” close to the axle shaft flange so it will be visible while taking photos of the nuts/studs. 3. TEMPORARILY REMOVE BRAKE LINE HARDWARE TO ALLOW ACCESS TO UPPER RIGHT NUT a. Remove the outermost bolt that secures the hard brake line to the axle housing. 13 NOTE: Some parts removed for visibility 4. TORQUE STEP 1: CHECK TO SEE IF ALL FOUR (4) NUTS ON RIGHT SIDE MOVE AT 20 Nm a. Set torque wrench to 20 Nm (204 kgf cm, 177 in. lbf). b. Tighten each nut to 20 Nm (204 kgf cm, 177 in. lbf) following the tightening sequence shown in the image to the left. • Only move the brake line enough to create clearance for a torque wrench. Excessive movement could result in permanent damage to the brake line. • Be careful not to scratch or cause other damage to the brake line. • Do NOT use extensions with the torque wrench. c. Check the matchmarks to see if the nuts moved. If ALL FOUR (4) moved, this side has failed inspection. Proceed to section VIII. AXLE SHAFT COMPONENT REPLACEMENT Yes No Did ALL FOUR nuts move on the LEFT (Driver) Side when torqued to 20 Nm? Proceed to step 5 Front of Vehicle 14 NOTE: Some parts removed for visibility 5. TORQUE STEP 2: INCREASE TORQUE TO 95 Nm a. Set the torque wrench to 95 Nm (969 kgf cm, 70 ft. lbf) b. Tighten each nut to 95 Nm (969 kgf cm, 70 ft. lbf) following the tightening sequence shown to the left. • Only move the brake line enough to create clearance for a torque wrench. Excessive movement could result in permanent damage to the brake line. • Be careful not to scratch or cause other damage to the brake line. • Torque nuts to 95 Nm (969 kgf cm, 70 ft. lbf). DO NOT use torque specification listed in Repair Manual. • When torquing the nut apply torque in a smooth slow rotation. DO NOT quickly apply torque. • Do NOT use extensions with the torque wrench. Front of Vehicle 15 c. Photograph the matchmark positions post-torque and upload 2 photos to website (front and rear of axle; 2 nuts per photo). Proceed to section VIII. AXLE SHAFT COMPONENT REPLACEMENT Yes No Were any nuts missing, or were all 4 nuts on 1 or both sides torqued less than 20 Nm? Proceed to section XII. REINSTALL BRAKE HARDWARE AND WHEELS Example: Rear of Right Side Example: Front of Right Side 16 VIII. AXLE SHAFT COMPONENT REPLACEMENT 1. REPLACE COMPONENTS LISTED BELOW Replace all parts on the side(s) that failed inspection ONLY. Failed Side Part Number Part Description Quantity LEFT (Driver) Side 90468-A0007 Clip (For Brake Tube)* 1 47804-60011 Cover Sub-Assy, Disc Brake Dust, Rear LH 1 42460-0C020 Hub & Bearing Assy, Rear Axle, LH 1 90208-A0001 Washer (For Rear Axle Shaft)* 1 42423-34040 Retainer, Rear Axle Bearing Inner* 1 90520-46014 Ring, Snap (For Rear Axle Shaft)* 1 90310-A0004 Seal, Oil (For Rear Axle Shaft)* 1 90301-A0015 Ring, O (For Rear Axle Bearing)* 1 90114-A0004 Bolt, Serration* 4 90178-A0057 Nut, Flange* 4 94622-41200 Washer, Plate* 4 RIGHT (Passenger) Side 90468-A0007 Clip (For Brake Tube)* 1 47803-60011 Cover Sub-Assy, Disc Brake Dust, Rear RH 1 42450-0C030 Hub & Bearing Assy, Rear Axle, RH 1 90208-A0001 Washer (For Rear Axle Shaft)* 1 42423-34040 Retainer, Rear Axle Bearing Inner* 1 90520-46014 Ring, Snap (For Rear Axle Shaft)* 1 90310-A0004 Seal, Oil (For Rear Axle Shaft)* 1 90301-A0015 Ring, O (For Rear Axle Bearing)* 1 90114-A0004 Bolt, Serration* 4 90178-A0057 Nut, Flange* 4 94622-41200 Washer, Plate* 4 *Same part number used for both sides a. Axle Shaft Removal: AXLE AND DIFFERENTIAL: REAR AXLE SHAFT: REMOVAL; 2022 MY Tundra Tundra HV [11/2021 – 05/2022] (RM100000001Z2DK) AXLE AND DIFFERENTIAL: REAR AXLE SHAFT: REMOVAL; 2022 MY Tundra Tundra HV [05/2022 – ] (RM1000000022DH0) NOTE: Differential oil will leak once you begin to separate the axle shaft from the axle housing. Be prepared with a drain pan and rags. 17 b. Axle Shaft Disassembly: AXLE AND DIFFERENTIAL: REAR AXLE SHAFT: DISASSEMBLY; 2022 MY Tundra Tundra HV [11/2021 – ] (RM100000001Z2DL) NOTE: DO NOT remove Brake Drum Oil Deflector during disassembly (step 4 in RM). PART NAME 1 BRAKE DRUM OIL DEFLECTOR (DO NOT REMOVE) 2 REAR AXLE HUB AND BEARING ASSEMBLY 3 REAR AXLE SHAFT 4 REAR AXLE SHAFT SNAP RING *1 REAR AXLE BEARING INNER RETAINER *2 REAR AXLE SHAFT WASHER *3 PARKING BRAKE PLATE TO REAR AXLE HOUSING BOLT *4 PARKING BRAKE PLATE SUB-ASSEMBLY *5 REAR AXLE HUB BOLT (DO NOT REMOVE) – – ● Non-reusable part – – 18 c. Axle Shaft Reassembly: AXLE AND DIFFERENTIAL: REAR AXLE SHAFT: REMOVAL; 2022 MY Tundra Tundra HV [11/2021 – 05/2022] (RM100000001Z2DK) d. Axle Shaft Installation: AXLE AND DIFFERENTIAL: REAR AXLE SHAFT: REMOVAL; 2022 MY Tundra Tundra HV [11/2021 – 05/2022] (RM100000001Z2DK) AXLE AND DIFFERENTIAL: REAR AXLE SHAFT: REMOVAL; 2022 MY Tundra Tundra HV [05/2022 – ] (RM1000000022DH1) • GTS (Techstream) is required to bleed the brakes on hybrid models. Be sure to follow the correct Repair Manual procedure for brake bleeding. Example: BRAKE SYSTEM (OTHER): BRAKE FLUID (for HEV Model): BLEEDING; 2022 MY Tundra Tundra HV [05/2022 – ] (RM1000000022AI4) • Rear axle nuts should be torqued to 95 Nm (969 kgf cm, 70 ft. lbf). Do NOT use Repair Manual torque specification for these nuts. IX. ADD DIFFERENTIAL OIL 1. Add differential oil (step 2 in RM). MAINTENANCE: DIFFERENTIAL OIL: REPLACEMENT; 2022 MY Tundra Tundra HV [11/2021 – 05/2022] (RM100000002048H) MAINTENANCE: DIFFERENTIAL OIL: REPLACEMENT; 2022 MY Tundra Tundra HV [05/2022 – ] (RM1000000022LTS) 19 X. REINSTALL BRAKE HARDWARE AND WHEELS 1. REINSTALL BRAKE HARDWARE a. Reinstall the bolts that secure the hard brake line to the axle housing. Torque Specification: 19.5 Nm (199 kgf cm, 173 in. lbf) Left (Driver) Side Right (Passenger) Side 2. CHECK FOR BRAKE FLUID LEAKS a. Inspect both brake line joints for leaks where the hard brake tube connects to the flexible hose. If leaks are found, refer to Repair Manual for tightening procedure and torque. Left (Driver) Side Right (Passenger) Side 20 3. REINSTALL REAR WHEELS a. Reinstall Rear Wheels and torque according to the sequence and specification below. Torque Specification: • Steel Wheel: 209 Nm (2131 kgf·cm, 154 ft.·lbf) • Aluminum Wheel: 131 Nm (1336 kgf·cm, 97 ft.·lbf) Torque Pattern: 21 XI. TEST DRIVE AND RE-TORQUE 1. TEST DRIVE VEHICLE ON THE HIGHWAY FOR AT LEAST TWO MILES a. Test drive conditions should include acceleration, deceleration, braking, and bumps. 2. RE-TORQUE NUTS ON THE SIDE(S) THAT HAD AXLE COMPONENTS REPLACED. a. Lift the Vehicle b. Remove the rear wheel(s) on the side(s) that had axle components replaced. c. Remove the bolts that secure the hard brake line to the axle housing on the side(s) that had axle components replaced. d. Remove the clip where the hard brake line connects to the flexible brake hose on the side(s) that had axle components replaced. e. Torque the four nuts to 95 Nm in the sequence below on the side(s) that had axle components replaced. Left (Driver) Side Torque Sequence Right (Passenger) Side Torque Sequence NOTE: Some parts removed for visibility NOTE: Some parts removed for visibility Front Front 22 XII. REINSTALL BRAKE HARDWARE AND WHEELS 4. REINSTALL BRAKE HARDWARE a. Reinstall the bolts that secure the hard brake line to the axle housing. Torque Specification: 19.5 Nm (199 kgf cm, 173 in. lbf) Left (Driver) Side Right (Passenger) Side 5. CHECK FOR BRAKE FLUID LEAKS a. Inspect both brake line joints for leaks where the hard brake tube connects to the flexible hose. If leaks are found, refer to Repair Manual for tightening procedure and torque. Left (Driver) Side Right (Passenger) Side 23 6. REINSTALL REAR WHEELS a. Reinstall Rear Wheels and torque according to the sequence and specification below. Torque Specification: • Steel Wheel: 209 Nm (2131 kgf·cm, 154 ft.·lbf) • Aluminum Wheel: 131 Nm (1336 kgf·cm, 97 ft.·lbf) Torque Pattern: 24 19 19 = 2019 20 = 2020 21 = 2021 22 = 2022 23 = 2023 Etc… Year Campaign is Launched 19TA01 T T = Toyota L = Lexus Vehicle Make A A = Safety Recall Remedy B = Safety Recall Interim C = Special Service Campaign D = Limited Service Campaign E = Customer Support Program F = Emissions Recall G = Consumer Advisory H = Equipment Recall (May use other characters in unique cases) Field Action Category and Phase 01 01 = 1st Field Action of the year 02 = 2nd Field Action of the year 03 = 3rd Field Action of the year (The sequence is unique for each Field Action category) (May use other characters in unique cases) Field Action Sequence Examples: 19TA01 = Launched in 2019, Toyota, Safety Recall Remedy Phase, 1st Safety Recall Launched in 2019 20TC02 = Launched in 2020, Special Service Campaign, 2nd Special Service Campaign Launched in 2020 21TE05 = Launched in 2021, Customer Support Program, 5th Customer Support Program Launched in 2021 ◄ VERIFY REPAIR QUALITY ► • Confirm all axle flange nuts were installed and torqued properly. • Confirm brake line bolts were installed and torqued properly. • Confirm wheels were installed and torqued properly. • Confirm that there are no fluids leaking from the rear axle area. • Confirm that the brake lines have not been deformed, scratched, or damaged in any way. If you have any questions regarding this instruction, please contact your regional representative. APPENDIX A. PARTS DISPOSAL In accordance with Federal law, please make sure all recalled parts (original parts) removed from the vehicle are disposed of in a manner in which they will not be reused, unless requested for parts recovery return. B. CAMPAIGN DESIGNATION DECORDER

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