MrHC1983

Well conclusion to this was....... Toyota covered it out of warranty and the noise is gone. Back to its normal self. We did also buy a Holden Acadia to replace our secondary car (VE Commodore) as having the Kluger go down was not good for our family. So we needed a second 7 seater. We'll be keeping the Kluger .... depsite this failure it's still a great car and props to Toyota for covering it.

No GX. Sorry I thought I replied? I presume you've already sorted this.

So had the car looked at. Diagnosed a failed/faulty transfer case. Quoted $4500-4600 for repair. So I'v applied for Toyota to cover it. The car I've only owned for a bit over 3 years. How rediculus.... This things been babied really.... always serviced, mostly just used for work and taking the kids everywhere.... I'm probably just going to sell it once it's fixed. I love the thing, there's nothing as good as them but there's just alot that can go wrong and they are expensive. I mean the 2GR-FKS ...... and previous FE's had issues water pumps, seals, now mines had the transfer case.... I've owned Holdens all my life, never had issues with them. I think I'll go back (despite them being gone) to what I was originally going to buy which was a Holden Acadia. I'll file a complaint with the ACCC as well....... I mean it's expensive and Toyota's warranty on my car was like 5 years, 100,000kms? ..... For how much was my car new......... 50-60k..... CRAZY

I rang Toyota to get quote, they were going to charge $500+ just for one rear wheel bearing.... So at that point... I just ordered all four wheel bearings myself, the stuff to replace them and did that myself. The backs were pretty simple, the fronts were pressed in ones. Biggest issue firstly was the axle nut with the notch, so easy to damage the cv shaft threads. The front and rear drivers side bearings were definately noisy the passenger side front/rear was OK. Anyway after all that, the noise is still there. Makes me a sad panda. I then drained the transfer case, rear diff and trans fluid..... to check. The transfer case had cloudy oil and metal spikes on the magnet. The rear diff and transmission seemed fine. I refilled the trans as per the TechStream ATF Fluid temp method as outlined by Toyota. I now have the car booked in for Toyota to take a look. Not a happy camper.... I've always done the fluids, the correct oils, as per the service intervals.

So I jacked the front back up and managed to get the wheels to rotate more freely....... and the front passenger bearing I am pretty sure has had it. I went one way and another, there was a fair bit of transmission, transfercase chatter....... but then on just that one side it sounded like a metal sound clacking when rolling it a certain way, upon taking the wheel and brake rotor off etc......... it seems pretty clear the bearings have gone. It's very notiable when you take the rotor etc off. I'm going to toss up now ordering a press kit and the bearing vs just taking it down to toyota etc to ensure thats the diagnosis. It's around $200-300 to do it yourself with a press kit so I presume with Toyota it will be more up around $600-800. I'm thinking of doing it myself because based on experience normally when one goes the others arn't far behind..... my car only has 140,000kms on it...... It is what it is.

So over Christmas last year I did went down some dirt roads/plantation type stuff but went through some dirty water/mud type stuff (just your average puddle type stuff, nothing too deep and I was gentle and cautious when doing through them)........ anyway my Klugers in the past month developed a noise that I've been trying to narrow down. So you can hear it essentially ONLY in the cabin about 30-60km/h... it gets faster and turns into a small hum at 100 barely noticeable. It's like a ner ner ner ner ner (faster or slower) and then due to 100kmh is more of a hum then anything. You absolutely cannot hear it outside the car, we've done windows down, drive by's. I've had the car on the stands in gear with all four wheels running.... (not safe enough to do the 30-60kmh) but idling along in drive. All the bearings sound OK. Wobble test seems OK. I did note at one point when I rotate one of the back wheels with the other on the ground it was smooth if you had your hand on the CV in the middle of it..... but with both wheels off the ground it has like a gap/notch as you turn the wheels. Not 100% sure if thats right, it's a bit of a weird open diff thing so that might be normal. I could pick anything, front transfer case, universal joints, rear diff, cv's and or bearings......... alot to choose from. Sounds generally travel especially in a AWD..... Be so much easier to find in a FWD or RWD! My next step is to strap a camera or something under the car and go for a drive see if I can pick it up under the car.... I'm getting close to taking it to Toyota as really you need a lift to really chuck a scope on them and work it out but I don't want to be defeated yet as I do all the cars here always have. Considering the waters I went through I'm thinking it's a bearing somewhere or the rear diff. I changed the transfer case and the rear diff oils..... one was normal colour, one was black with possible metal bits on it. I'll post again when I find out wtf it is, I got a recording of the sound I may upload and link as well. I used to own a VE SS Commodore custom cam etc all done by me, this AWD thing is very much a pain for DIY diagnosis.

If anyone needs a stock headunit I still have mine and could sell it. I dunno if they vin lock any of these or not but mine was working perfectly when I removed it. It's just been sitting in a box ever since. I'll happily sell it for like $500 shipping ontop. It's from a 2017 model.

I just bought a 2017 GX Kluger ....... gutted the original headunit for a 10 inch android based one. Not perfect as it's made for LHD but does carplay and is a hell of alot more functional then Toyotas crap..... haven't figured out the steering wheel controls just yet (had two days so far). So if no luck maybe that? ..... or hunt down a used genuine one - very easy to fit or replace.