24TA05 – Potential Axle Shaft Separation – 2022-2023 Toyota Tacoma

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February 27, 2024 NHTSA CAMPAIGN NUMBER: 24V152000

Rear Axle Shaft Separation

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

 

NHTSA Campaign Number: 24V152

Manufacturer Toyota Motor Engineering & Manufacturing

Components POWER TRAIN

Potential Number of Units Affected 381,199

 

Summary

Toyota Motor Engineering & Manufacturer (Toyota) is recalling certain 2022-2023 Tacoma vehicles. The axle shaft sub-assembly may separate from the axle housing due to debris causing improperly secured fasteners.

 

Remedy

Dealers will inspect the rear axle assembly, tighten the axle retaining nuts as necessary, and repair or replace any damaged components, free of charge. Owner notification letters are expected to be mailed April 13, 2024. Owners may contact Toyota customer service at 1-800-331-4331. Toyota’s numbers for this recall are 24TB05 and 24TA05.

 

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

 


SAFETY RECALL 24TA05 (Interim Notice 24TB05)
Certain 2022-2023 Model Year Tacoma
Potential Axle Shaft Separation

On February 27,2024, 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 certain 2022-2023 model year Tacoma vehicles.

 

Condition 

Welding debris left on the ends of the rear axle assembly during manufacturing could cause certain retaining nuts to loosen over time and eventually fall off, potentially causing a part to separate from the axle. If separation occurs, this can affect vehicle stability and brake performance, increasing the risk of a crash.

 

Remedy 

Toyota is currently preparing the remedy for this issue.  When the remedy is available, Toyota dealers will inspect the rear axle assembly and retighten the axle retaining nuts at no cost to customers. If axle components are damaged as a result of this condition, they will be repaired or replaced, if necessary, based on inspection criteria. Toyota estimates the remedy can be available in the second quarter of 2024.

 

Covered Vehicles

There are approximately 381,200 vehicles covered by this Safety Recall. Approximately 6,400 vehicles involved in this Safety Recall were distributed to Puerto Rico.

 

Owner Letter Mailing Date

Toyota will notify owners by late April of 2024.

 


Description of Problem:

The subject vehicles are equipped with a rear axle assembly, which includes axle shaft sub-assemblies secured to welded-on axle housing ends on each side of the assembly. Each axle shaft sub-assembly is secured to the axle housing using studs and retaining nuts. During a welding process in a certain production period at a specific supplier’s manufacturing facility, an improper welding spatter guard mounting setup was used, and spatter from the welding could have landed on the retaining nut seating surface. In this condition, the joint retention could be affected; the retaining nuts could loosen over time and potentially fall off, causing one or both axle shaft sub-assembly to begin to separate from the axle housing. If the vehicle is operated with loosened nuts, the driver may experience a vibration, hear an abnormal noise, and/or observe leaking of differential oil. If an axle shaft separation occurs, vehicle stability and brake performance could be affected, increasing the risk of a crash.

 

Chronology of Principal Events:

Late October 2023 – December 2023
In late October 2023, during a receiving inspection of the Tacoma rear axle assembly at a vehicle assembly plant, Toyota found weld spatter on the retaining nut seating surface of the axle housing end. Toyota began to investigate other rear axle assemblies and recover parts.

During the investigation, Toyota and the supplier found issues within the supplier’s inspection process for completed axle assemblies. Toyota and the supplier also found issues with a welding spatter guard design change which was implemented in May 2022 to standardize the design of spatter guards between welding lines. This change resulted in variability when mounting the welding spatter guard to the equipment and allowed weld spatter to land on the retaining nut surface of the axle housing end. In parallel, Toyota recovered parts from the supplier’s warehouse which were later used for joint retention testing to assess the stud axial tension.

January 2024 – February 2024
During January 2024, Toyota performed joint retention testing on the recovered parts to determine the effect of changes to the retaining nut seating surface condition caused by weld spatter. The results of this testing indicated that the integrity of the joint between the seating surface of the axle housing end and retaining nuts could be affected by changes to the retaining nut seating surface condition due to weld spatter. Toyota concluded that the presence of weld spatter on the nut seating surface could affect the axial tension and reduce the initial clamping force between the axle housing end and retaining nuts beyond the design minimum required specification. This could occur at either or both ends of the axle, potentially causing the retaining nuts to loosen over time.

Based on the investigation and Toyota’s engineering judgement, it was determined that, if the retaining 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 separation occurs, this can affect vehicle stability and brake performance, increasing the risk of a crash.

February 21, 2024
Toyota decided to conduct a voluntary safety recall campaign.
As of February 20, 2024, based on a diligent review of records, Toyota’s best engineering judgement is that there are 0 Toyota Field Technical Reports and 0 warranty claims that have been received from U.S. sources that relate or may relate to this condition and 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, dealers will inspect the rear axle assembly and retighten the axle retaining nuts. If weld spatter is found, it will be removed. Axle components which are damaged may be repaired or replaced based on inspection criteria, if necessary.

 


2 Affected Products

Vehicle

MAKE MODEL YEAR
TOYOTA TACOMA 2022-2023

 


4 Associated Documents

Defect Notice 573 Report

RCLRPT-24V152-2601.PDF 215.341KB

 


Recall Acknowledgement

RCAK-24V152-8115.pdf 704.209KB

 


Manufacturer Notices(to Dealers,etc) – Toyota Date: February 27,2024 SAFETY RECALL 24TA05 (Interim Notice 24TB05)

RCMN-24V152-8557.pdf 194.205KB

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February 27, 2024 DEFECT INFORMATION REPORT Chronology of Principal Events

RMISC-24V152-7847.pdf 126.438KB

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Latest Recalls Documents

For the Latest and Most recent Recall Information Visit the link below…

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=24V152&docType=RCL

 


 

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