2020 Tundra needs new front differential

Sorry about your issues. Things happen.

Paging @Owen Lucas

My guess is he will tell you to get an independent appraiser then go from there. I will add you don't want body shops doing mechanical / suspension work - even if they say they can.
No, he was very clear that the dealership is going to replace anything damaged that isn't body work. He claims it is just the bumper but I haven't seen it yet. I'm at work and he's leaving early so I'm meeting him tomorrow after 7am to take a look.

As for things happening? I agree. I thanked him for being upfront and he reiterated that people make mistakes and all that matters is what you do after the mistake to make it right. That left me optimistic.
 
No, he was very clear that the dealership is going to replace anything damaged that isn't body work. He claims it is just the bumper but I haven't seen it yet. I'm at work and he's leaving early so I'm meeting him tomorrow after 7am to take a look.

As for things happening? I agree. I thanked him for being upfront and he reiterated that people make mistakes and all that matters is what you do after the mistake to make it right. That left me optimistic.
I meant what @Owen Lucas would tell you, not the dealer.

If there is no paint and no frame damage then I would just let them change the parts. They want it gone more than you do. I would still ask them to pay for you to get the appraiser - so nothing is missed.
 
I meant what @Owen Lucas would tell you, not the dealer.

If there is no paint and no frame damage then I would just let them change the parts. They want it gone more than you do. I would still ask them to pay for you to get the appraiser - so nothing is missed.
Bear with me here...just working this out in my head during a busy work todayy. Theoretically, if they replace what they need to replace and align the vehicle and they are able to get everything within spec, that's a decent indication the frame and remaining suspension parts are good?
 
Oy vey...

Just got a phone call from the service manager. Everything was done and tech put the wheel on with no lug nuts and then tried to drive it out for the test drive and the wheel came off and there's suspension and bumper damage. I can use any body shop I want, they will replace anything that needs replacing, and he put a Highlander aside for me for a loaner.

If it wasn't warranty work...I wouldn't have brought it to the dealership monkeys...
Sorry about your issues. Things happen.

Paging @Owen Lucas

My guess is he will tell you to get an independent appraiser then go from there. I will add you don't want body shops doing mechanical / suspension work - even if they say they can.


I'd have the shop do the suspension work, verified with OEM parts alignment etc. Body work. If its just the facebar on the bumper, they can do that as well.

Is the fender or apron (inner fender behind fender liner) bent?

Any body work I'd take it to a Toyota Approved body shop. Many dealers own their body shops or at least have a certified shop that they have a relationship with.

You should be able to take it to any shop, if you are filing an insurance claim that is, which in this case, might not be the best move for reporting purposes, using their shop would be ideal. The wheel goof up is most likely an outlier and hopefully they get the message across to the new tech and shop that this repair should be perfect...because you will be inspecting with a fine tooth comb!
 
Bear with me here...just working this out in my head during a busy work todayy. Theoretically, if they replace what they need to replace and align the vehicle and they are able to get everything within spec, that's a decent indication the frame and remaining suspension parts are good?
You can have them ask the shop to set it up on a frame machine, bolt the frame to the bench and measure it out.

The suspension mounting points is what I'd be worried about if they got bent. It need a good inspection on a lift. Probably lots of scratching to the frame, cradle, hopefully not the body.
 
You can have them ask the shop to set it up on a frame machine, bolt the frame to the bench and measure it out.

The suspension mounting points is what I'd be worried about if they got bent. It need a good inspection on a lift. Probably lots of scratching to the frame, cradle, hopefully not the body.
Here is an email I was thinking of sending. I would appreciate your (and other's) feedback.

"Thank you for speaking with me today regarding the incident involving my 2020 Tundra Platinum where the front wheel was not properly secured after service causing it to separate during the test drive, causing damage to the vehicle. I appreciate the dealership agreeing to repair all resulting damage and allowing me to choose the body shop.

Following the wheel separation incident during the test drive, I would like the vehicle inspected by an independent shop of my choosing prior to final repairs to ensure there is no hidden suspension, steering, drivetrain, or structural damage.

  • Did the wheel fully separate from the hub? Did the rotor hit pavement? How fast was the tech going approximately? My concern being damage to the hub, rotor/caliper, wheel studs, knuckle, CV axle, suspension, and frame.
  • I’m formally requesting:
  • 1. Pre-repair inspection report from an independent shop of my choosing
  • 2. Pre-repair alignment/frame measurements
  • 3. Post-repair alignment measurements
  • 4. Written incident report
Given the nature of the incident and the weight of the vehicle, I believe an independent inspection is appropriate before accepting the completed repairs.

Please let me know how you would like to coordinate this process."
 
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I'd have the shop do the suspension work, verified with OEM parts alignment etc. Body work. If its just the facebar on the bumper, they can do that as well.

Is the fender or apron (inner fender behind fender liner) bent?

Any body work I'd take it to a Toyota Approved body shop. Many dealers own their body shops or at least have a certified shop that they have a relationship with.

You should be able to take it to any shop, if you are filing an insurance claim that is, which in this case, might not be the best move for reporting purposes, using their shop would be ideal. The wheel goof up is most likely an outlier and hopefully they get the message across to the new tech and shop that this repair should be perfect...because you will be inspecting with a fine tooth comb!
This is not going to be an insurance claim on my part. Service manager stated he already spoke to the general manager and Toyota corporate and everything needed has been approved.

The dealership that did the damage is not a certified Toyota body shop but the dealership in Worcester about 20 miles away is certified. Ask them send it there?
 
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This is not going to be an insurance claim on my part. Service manager stated he already spoke to the general manager and Toyota corporate and everything needed has been approved.

The dealership that did the damage is not a certified Toyota body shop but the dealership in Worcester about 20 mile away is certified. Ask them send it there?
  • Did the wheel fully separate from the hub? Did the rotor hit pavement? How fast was the tech going approximately? My concern being damage to the hub, rotor/caliper, wheel studs, knuckle, CV axle, suspension, and frame.

  • I’m formally requesting:
  • 1. Pre-repair inspection report from an independent shop of my choosing
  • 2. Pre-repair alignment/frame measurements
  • 3. Post-repair alignment measurements
  • 4. Written incident report

I would take it to the Toyota Certified body shop.

Sometimes shops of competing brands like to stick it to each other, and charge as much as possible in my experience, which might be good for you here.

The alignment request should not be an issue, before and after is standard with suspension work.

I think frame measurment is excellent peace of mind, especially if they can get the tram to measure the mounting points for the shock tower etc.

Incident report. This will likely be just an estimate with additional notes. I don't see a tech writing a document free-style but an email should be helpful for documentation.

If the rotor contacted the ground, or inside of the wheel, replacing it would be helpful. Have them take photos of everything. Minor scratches and scrapes fromt he incident should be correctly repaired, not just covered up with undercoat.
 
I would take it to the Toyota Certified body shop.

Sometimes shops of competing brands like to stick it to each other, and charge as much as possible in my experience, which might be good for you here.

The alignment request should not be an issue, before and after is standard with suspension work.

I think frame measurment is excellent peace of mind, especially if they can get the tram to measure the mounting points for the shock tower etc.

Incident report. This will likely be just an estimate with additional notes. I don't see a tech writing a document free-style but an email should be helpful for documentation.

If the rotor contacted the ground, or inside of the wheel, replacing it would be helpful. Have them take photos of everything. Minor scratches and scrapes fromt he incident should be correctly repaired, not just covered up with undercoat.
Thank you, Sir.

I appreciate your guidance!
 
Service manager was very nice. Wheel came off completely at between 2-5 mph and it did hit the rotor. The offending tech was one of their master techs who according to the service manager they sent home yesterday because he was so distraught over this. He stated HR was involved and they had to write up a critical incident report. He also wanted to be there this morning to apologize in person but he had a family wedding. True or not, I appreciate the sentiment. Besides the front differential, he's also comping the coolant change and tire rotation...lol.

Here is a picture. Wheel obviously impacted into the top of the wheel well/fender. He had no problem sending the truck to the Toyota certified collision dealer in Worcester and said he'd personally call them to let them know what's going on and to fix anything they deemed damaged by the incident and that I don't have to coordinate anything and he'll be in touch. I'll shoot the service/collision manager in Worcester an email to introduce myself. Driving a 2026 Highlander Hybrid until I get this back.

Your collective thoughts are always appreciated...

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Here is a picture. Wheel obviously impacted into the top of the wheel well/fender.
Doesn't look so bad! I'd have the inside drum of the wheel checked to make sure the wheel studs / rotor didn't damage the spokes or drum.

The shop will have to blend the hood and door for color match on a silver which includes all detrimming etc. The door emblem might be retapable, maybe not, some components like belt moldings aren't always reusable.
 
On a positive note. I'm looking at vehicles that have the Toyota hybrid system and they gave me a hybrid Highlander. I'm pleasantly surprised by how well it drives and how seamlessly the hybrid system endlessly transitions from electric to gas engine and back again.

Wanted test drive a new RAV4 but they have none to drive.

I did test drive a Crown Insignia, loved everything except the lack of headroom.
 
It took until Post #32 for the real solution.

Option 1: fix it forever
Option 2: install the same parts and expect a different result = definition of insanity

This can all be done with the front pig still in the vehicle. And an indy probably woulda remembered to install lugnuts, too..... :)
Insanity is paying anything at all right now while it's under warranty. I'm no mathematician, but if the same thing happens in the same time/mileage, it will happen on a 13 year old truck with 150k miles. If I still have it at that point, and I likely will not, I can pay an indy shop then IF it happens. Why pay ANYTHING right now if I don't have to?
 
It took until Post #32 for the real solution.

Option 1: fix it forever
Option 2: install the same parts and expect a different result = definition of insanity

This can all be done with the front pig still in the vehicle. And an indy probably woulda remembered to install lugnuts, too..... :)

I maintain a 2021 Tundra 4x4 this looks like a must do before its first front diff oil change.
I changed the rear diff oil a while ago but hadn't changed the front diff oil yet because of this problem still floating around to this day. Plus I don't want to waste perfectly good Ravenol oil.
 
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I maintain a 2021 Tundra 4x4 this looks like a must do before its first front diff oil change.
I changed the rear diff oil a while ago but hadn't changed the front diff oil yet because of this problem still floating around to this day. Plus I don't want to waste perfectly good Ravenol oil.
I keep trying to get detailed dims of their tools 'cause I wanna just make myself a set. Partially I'm cheap and partially I like working with my hands (and my machine tools)

I can find dims for the Taco/4R but not the Tundra which uses larger stuff. As an example, if you just scroll thru assorted Amazon and ebay photos of tool copies, you can usually find the dims. But again, this is for the smaller Toy diffs
Screenshot_20260510_145212_Chrome.webp

I've done this for lots of assorted crude tools like bushing drivers, ie "stolen" dimensions from product listings like this.
 
Insanity is paying anything at all right now while it's under warranty. I'm no mathematician, but if the same thing happens in the same time/mileage, it will happen on a 13 year old truck with 150k miles. If I still have it at that point, and I likely will not, I can pay an indy shop then IF it happens. Why pay ANYTHING right now if I don't have to?

I'd rather save time and money. I'd rather save over $900.00 by buying the part and install kit that fixes the problem for good, and not buying the extended warranty. Then there's the time of taking the truck to the dealership. Having it diagnosed, and 'fixed' back to it's failure-prone state, and now more time to fix their mistake. Hopefully back to the condition it was.

But whatever works for you.

I hope the glaring oversight of not installing the lug nuts is not representative of all of their work.
 
I'd rather save time and money. I'd rather save over $900.00 by buying the part and install kit that fixes the problem for good, and not buying the extended warranty. Then there's the time of taking the truck to the dealership. Having it diagnosed, and 'fixed' back to it's failure-prone state, and now more time to fix their mistake. Hopefully back to the condition it was.

But whatever works for you.

I hope the glaring oversight of not installing the lug nuts is not representative of all of their work.
The extended warranty wasn't just because of the needle bearing issue. It was also for cam tower leaks and because they removed the transmission cooler in 2020 and for any other issues that arise. Essentially, insurance and peace of mind.

I'm not replacing the needle bearing myself so it's not just the part, it's the part and labor for someone else to do it. At worst, I broke even financially but again that doesn't factor in peace of mind, and that warranty is still in effect for 2 more years and 30k miles so who knows what else comes up.

As for the mistake...things happen. All I care about is they make it right.
 
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