My 2023 Toyota RAV4 Is the Most Frustrating Car I’ve Ever Owned, 14K Miles In, A New Transfer Case, 2 Weeks at the Dealer, and It’s Doing It Again

Is Toyota's reliability slipping?

A Toyota owner's 2023 RAV4 required a transfer case replacement and five seals at just 14,600 miles. If that wasn't bad enough, the clunk persisted even after the dealer was supposed to have made the repairs.

Did the Toyota dealer do all the work required to fix LaVella Brown Waller's 2023 Toyota RAV4? She says in a RAV4 Owners Facebook post that the problems should have been fixed, but after two weeks at the dealer, it's doing the same thing. 

You can imagine her frustration.  

The aroma of coffee in the customer waiting area did little to soothe LaVella's frayed nerves as she stared at the service invoice. "Transfer case replaced, five seals, warranty coverage, no charge to the customer," she muttered to herself.

Her faith in Toyota's legendary reliability is in question. 

Eight days without her 2023 RAV4 Limited AWD had been an inconvenience, but the prospect of finally having her car back, its perplexing "clunk" gone, had kept her spirits up. 

The service advisor had assured her the new transfer case was the definitive solution. "You'll be good to go, ma'am," he'd chirped, handing her the keys to her newly-fixed RAV4 SUV.

That was yesterday. 

Today, after the problem was supposedly fixed, the clunk returned, and now this RAV4 owner is questioning Toyota and her RAV4. 

"Aren't Toyotas supposed to be reliable?" 

The question, laden with a mix of betrayal and disbelief, hung in the stale air of her garage. She'd bought the RAV4 with 14,600 miles on it, practically new. 

It was supposed to be a sensible, dependable choice for her daily commute and weekend escapes into the mountains. Instead, it was turning into a source of profound frustration.

Was she just unlucky? Or was this a deeper, more insidious problem?

The thought of returning to the Toyota dealership, of enduring another round of vague explanations and potentially more ineffectual repairs, made her stomach clench. 

Her reliable Toyota had become anything but, and the road ahead, both literally and figuratively, felt uncertain and full of unwelcome clunks.

LaVella says,

Has anyone had issues with their RAV4? I recently acquired a 2023 Toyota RAV4 Limited with 14,600 miles, equipped with AWD. I kept hearing a clunk whenever I was slowing down to stop. 

I took it to the local Toyota dealer for service, and they informed me that it needed a new transfer case and five seals. They've had it for eight days now, and I'm supposed to get it back today. 

Has anyone else experienced this issue, and what can I expect next? 

Update: After almost two weeks in the shop, I finally got my RAV4 back yesterday. It's still doing the exact same thing. No change. This is the most frustrating car I've ever owned. 

Aren't Toyotas supposed to be reliable? she says in frustration. 

What Are Other RAV4 Owners Saying? 

Let's take a look at some shared experiences from our community.

Courtney Kinnen says, "Ugh, I have a 2019 Toyota RAV4 Adventure, and mine just started making a clunk-clunk or thump-thump sound when I slowed down to stop yesterday." I barely drive the thing.

I bought mine certified pre-owned a year ago, and thankfully, it's still under warranty.

Gary LaRocca - This happened to my 2020 Toyota RAV4 Limited AWD, the first year of ownership. I am the original owner, and I've had both front and rear differentials replaced.

Korri McGrew - I had this same issue early with my 2019 RAV4 Adventure. Luckily, it was under warranty, but they did try to gaslight me at the dealer, telling me it was all in my head. I fired the dealer.

That raises the question: does the Toyota RAV4 have transfer case problems?

Some Toyota RAV4 models have experienced transfer case issues, particularly those related to noise and potential malfunctions. Specifically, some 2019 RAV4 Adventure and Limited AWD models have been reported to exhibit a buzzing or groaning noise from the front transfer case, especially at certain speeds. 

This issue can potentially affect the vehicle's handling and safety, making it a significant concern for RAV4 owners.

Here's a more detailed breakdown:

• Problem: Abnormal buzzing or groaning noise coming from the front transfer case, particularly at 20-30 mph when accelerating from a stop or decelerating.
• Cause: The noise is often reported after the vehicle has been driven for a while, suggesting a potential issue with the transfer case's operation under specific conditions.
• Resolution: Toyota has issued a service bulletin (T-SB-0086-19) addressing this issue in 2019 RAV4 models. Some owners have reported success with a software update, while others have required a complete replacement of the rear differential assembly.
• Note: Some owners have reported difficulty getting Toyota to repair the issue, as the dealership may be unable to reproduce the noise. 

That raises the question: 

Did the Toyota dealer that LaVella took her RAV4 to replace the transfer case? 

The Toyota dealer likely replaced the RAV4's transfer case, but the technician may have performed inferior work on her car. The service invoice stated that they also replaced five seals. Could they have been improperly installed? 

It's essential to note that Toyota has implemented a Customer Support Program (CSP) (20TE03) to address a specific condition affecting the front transfer case electromagnetic clutch in 2019-2020 RAV4 Adventure and Limited models.

This program provides extended coverage for a specific issue related to the transfer case, offering potential solutions for affected owners. 

This CSP covers an abnormal buzzing or groaning noise that may occur at specific speeds (20-30 mph acceleration, 13-20 mph deceleration) when the AWD system is engaging or disengaging after the vehicle has been driven for 15 minutes or more. If this condition is confirmed, Toyota provides coverage to repair the car by replacing the front transfer case electromagnetic clutch and drain plug and potentially reprogramming the AWD ECU.

More RAV4 Details For Owners:

• Owner Reports: Some owners have shared experiences online where they've had issues that they suspect or have been told are related to the transfer case. However, it's important to note that these are individual reports and may not represent a widespread problem affecting all 2023 RAV4s.
• No Recalls for Transfer Case: There are no recalls specifically related to the transfer case for the 2023 Toyota RAV4. The CSP mentioned above provides extended coverage for a specific issue, but it's not a safety recall.
• Also Note: A class-action investigation has been reported regarding transmission problems in the 2021-2023 Toyota RAV4, with some owners experiencing issues such as jerking or lurching when shifting gears. While this concerns the transmission, issues with the transfer case can sometimes be related. 

Conclusion:

LaVella's 2023 Toyota RAV4 transfer case should not be performing the same function after it was replaced. It raises questions to which we don't have answers. Did the Toyota dealer replace the transfer case in her RAV4? Did the technician install it and the five seals properly? 

Do you own a Toyota RAV4, and have you experienced problems with the transfer case? If so, click the red Add New Comment link below and let us know.

Check out my Toyota RAV4 story: I Think My 2024 Toyota RAV4 Is a Lemon, With Only 12K Miles It Has Too Many Problems, I Bought a Toyota Because It’s Supposed To Be Reliable

I am Denis Flierl, a Senior Torque News Reporter since 2012. My 30+ year tenure in the automotive industry, initially in a consulting role with every major car brand and later as a freelance journalist test-driving new vehicles, has equipped me with a wealth of knowledge. I specialize in reporting the latest automotive news and providing expert analysis on Subaru, which you'll find here, ensuring that you, as a reader, are always well-informed and up-to-date. Follow me on my X SubaruReport, All Subaru, WRXSTI, @DenisFlierl, Facebook, and Instagram.

Photo credit: Denis Flierl via LaVelle