Differential Unit problems of the 2006 Toyota RAV4

We purchased a 2006 Rav4 limited the first week of March 2019. A rear differential coupling growl noise was noticeable a month after we purchased the vehicle. While driving the rear end started making a growling noise. In early January 2015 Toyota issued a warranty enhancement program (zf4) for years 2006-2012 Rav4 to have the defective bearing replaced, but they put an expiration date of April 30th 2017 or 9 years from the date of first use regardless of mileage. I can't understand how you can put an expiration date on a defective part. These bearings could go bad and seize at any time possibly causing an accident with injuries or even death. We happen to own two of these vehicles, same years, one making no noise and not going bad yet, but the other decided it was time. There should be a recall on this rear differential coupling bearing, not a warranty enhancement program. Toyota has already acknowledged a defect with the bearing by initiating a warranty enhancement program, you can't just say after April 30th 2017 no other bearings will fail and if they do we pass the buck on the problem. Thank you for hearing my concerns, I look forward to hearing back from you. I would like to debate the issue with one of their representatives with you listening, I'd rip'em apart. It is time these billion dollar companies own up to their mistakes and not pass the buck to the little guy. Thank you again, (xxxx). You can contact me at (xxxx). Parts of this document have been redacted to protect personally identifiable information pursuant to the freedom of information act (foia), 5 u. S. C. 552(b)(6).

Rear differential coupler is failing. Emitting an awful noise and getting worse. Spoke to Toyota customer service. They told me that the enhanced extended warranty has expired at the end of last year. I did not know about this, until the part has worn out. (defective) it is a $1400. Part plus labor to install. They cannot extend the enhanced extended warranty according to the rules that NHTSA has suggested. Don't you think it is time for NHTSA to require that Toyota renew this replacement, or call it a recall for their defective manufacturing process?.

Our 2006 Rav4 creates a growling sound from the rear differential area when driving at 35 to 40 mph. The sound goes away when accelerating above 40 mph. The noise is becoming more pronounced with time. Twice the vehicle was taken to a Toyota dealership and they were unable to identify the cause. Research online located technical service bulletin TSB-0080-13 which discusses symptoms very similar to what our rav is experiencing. A call to the Toyota dealership resulted in being informed that deterioration of the rear differential coupling due to contaminated bearing could be the problem, and that estimated cost of repair cost is $1,925. I asked if failure of the coupling could be catastrophic, causing loss of control. The answer was not likely unless driving on slippery surfaces. This vehicle is regularly maintained, and has not been in an accident. It is disappointing that we are looking at an impending failure of the drivetrain. Is this a flaw in the engineering/design that went into this vehicle? what else can be done beyond informing others in the interest of their personal safety?.