P2440 - AIP problems post 2010 models?

First post here, referred by a friend, and I apologize in advance for a whiny / rant introduction. Been a loyal TOYOTA guy since 2002, owning 4 different models, still drive my 2002 4runner with 250k miles, replaced my 2000 Tundra with 300k miles for a 2012 Tundra 4.6, and they have all performed well, till today.

On my 2nd Tundra now, a 2012 4.6 with 72000 miles. Been very happy until this week when the dreaded P2440 code popped up with check engine/trac off/ limp mode.

I knew this was a problem / defect with the 2007 - 2010 models, and was aware of the warranty repair extension. Family and 4 or 5 friends had the same problem on theirs as well, but were repaired under warranty. Thought the problem was corrected in the post 2010 models...obviously not. However 2 dealers have refused to repair under warranty...so it's a $2k - $4k out of pocket repair if I let a dealer do the work. I have my truck at a local shop being repaired since it is considerably less expensive, and frankly in limp mode don't think it safe to drive an hour up and down hills and highways to the closest dealer. I need a vehicle, so desperate times call for hard decisions.

My question is: Has anyone been successful getting Toyota to repair the AIP pumps/valves under warranty, or reimburse for out of dealership repair on post 2010 models? I contacted corporate asking for warranty repair or reimbursement, but have had no reply.

The two Toyota service reps told me that Toyota knows the problem still exists, but has not offered a warranty extension YET for newer models.

 

Update: just got the truck back from the local shop, and on the first cold start of the morning the P2440 secondary air pump / valve bank #1 check engine lights are back on, and back in limp mode. Clear the codes and back to normal once warmed up....
They replaced the bank 1 valve, and it did not cure the problem. Will be going back and leave the truck overnight to replicate the cold start codes.

I've gotten too old and don't have the diagnostics to work on vehicles anymore...still no response from Toyota corporate.
"Let's go places" has taken on a new meaning....

 

Welcome.

I had the same issue, with the same symptoms. I have a 2010 with 155k, the extended warranty stops at 150k. No amount of complaining or discussing resulted in any kind of discount or reimbursement for me, $2995 total at the dealership, both valves, pumps, lines and trumpet inlet tube all replaced accompanied with a 1 year warranty

If figure out a way to be reimbursed....even partially. several of us would be very thankful.

 

If you dont have a FFV then just do a bypass
https://rutechsolutions.com/products/aip47?variant=38455631364

 

Thanks for the welcome, CaptSpaulding.
Update: I worked my way painfully up the food chain at Toyota this week----> 2 dealerships which would not offer to help----->then letters that went unanswered to corporate (they won't put anything in writing is my guess)----> finally called corporate and worked my way up that food chain as far as I could get.----> The result is the friendly, but powerless folks at Toyota will not offer any assistance for reimbursement or repair.

Had the local independent shop replace the bank #1 air valve yesterday, and first cold start got the sames codes (P2440 ) check engine, trac off, limp mode again....so, it's moving into discussing replacing the whole system with the local shop. No reason to go to the dealer, they just charge eye-watering prices but they do hopefully have better diagnostics and trained techs.

On a positive side note; my oldest son is currently in Toyota Tech school. He will probably be making more money than a surgeon soon.

 

Hey Adam, thanks for the link. I was talking to the mechanic yesterday about by-passes. I had read about a Hewitt by-pass, but not his one by Rutechsolutions. Looking at it however it says for the 4.7 motor. My 2012 is a 4.6. And I honestly don't know if Toyota reflashed my computer or not at some point, so it may not work for me. Still looking for solutions.

Currently, I have a nice looking pile of Silver metal shaped like a 2012 Tundra sitting essentially dead in my front yard, and am facing a huge (to me) repair bill for a problem that Toyota has known about for 8 years, and I was "told" was resolved before I bought this truck at the dealership ( lesson: get it in writing ). I bought the truck as a low mileage CPO, and after talking to Toyota corporate, in truth it may have been traded-in and resold to me as a solution to their manufacturing problem/defect. I was hoping to get 250k miles out of this truck like I have in the past with Toyota products----> doubt that is going to happen.

Ironically, my wife and I drove to a local (about 70 miles away) dealership the night before my problems began to look at new 2019 Tundras. Toyota has been sending me enticing offers to trade-in for months with 0%APR. I jumped through hoops with them, had a contract in hand for a 2019 and decided to sleep on it. Next morning on start-up my problems began. I decided really don't want to go in debt for approaching $40k for 6 years at this point in life...so a $3000 repair might not be a bad alternative. Not real happy with Toyota right now.

That's life, stuff breaks and wears out, and I will move on.

 

Update #?
Got a phone call today from corporate (on a Saturday no less)....friendly, but worthless folks.

Two dealerships, several calls to corporate, and somehow no one can tell me if my problem will be covered under the CPO 8yr/100,000 mile limited power train warranty. I'm at 6yrs + a few months / 72000 miles. How difficult can that be? Not to get political, but Toyota's approach reminds me of "let us fix it, then we will tell you if it is covered under warranty."

The closest Toyota has come to addressing my request is for me to bring my truck in and for $100 they will tell me what's wrong. I already know what's wrong----it's diagnosed and information shared at the local and corporate level.

How about telling me if it's covered or not. I'm getting a run around from Toyota.

Doesn't anyone on this forum work for Toyota, or have some insight?

 

Case Closed:
After 2 weeks of back and forth with Toyota at the local and national level, they will not help with this repair.
* Repeatedly have been told by local Toyota techs that the AIP problem is real, and it continues beyond the 2010 year.
* After yesterday's final call talking to Toyota Warranty, where they even state "it's a BIG problem" Toyota's stance is "tough luck" and they will not even consider giving customers assistance.
* Toyota will not cover the P2440 / AIP bank #1 repairs beyond the 3yr original warranty. It is not drivetrain, nor is the problem emissions related they say, not a defect.

Make your own choices if you purchase one of these trucks.
The End.

 

CPO is a powertrain warranty, right? That is motor, trans, rear end components only. Not electronics, pumps, belts, injectors, etc. It is for catastrophic main component failure. They are pretty standard across brands.
This is still a sh-ite problem, and response from Toyota, regardless. Has been for years. Keep all records and receipts for any repairs, they *might* offer reimbursement in the future. They seem to drag ass and up the Vins and years they will cover, hoping people will get past 150k.
I find it troubling that no one has figured out a bypass for the FFV and later models though??

 

I have a 2007 Tundra...lights came on last week but thankfully no "limp mode". I only have 78k miles but my 10 year warranty has passed, so I'll be one of the unlucky ones if/when the dash lights up again. Local shop erased the codes and told me to get on the interstate and run the crap out of it. I did and no check engine light to date (3 days). I'm wondering....If this problem is so prevalent, why hasn't someone found a law firm to file a class action?

 

(Sorry, I haven't done a initial post in the welcome section but feel compelled to respond here bc I just dealt with the AIP issue recently)

At 229,xxx miles my 2007 DC 4x4's dash lit up like a Xmas tree and the truck was de-rating/in limp mode. I researched and found the Tundra dash light spreadsheet and using it deduced that most likely it was gonna be code P02442 for the AIP.

I then went to Oreillys and sure enough, they pulled a P02442 code. Being well over the 3yr/150,000 coverage I researched more & found the Hewitt Tech bypass kit. I installed it and now 4k miles later I haven't had a single issue.

Heck, it even gained me a couple MPGs. Yes I know that might sound crazy but it did. The new Falkens I installed afterwards promptly negated that gain though.

 

yep the Hewitt kit is great for that.

 

This is what I found out from Toyota about this issue, and I posted this in another thread:

This is what the Toyota dot com site says about my vehicle: There are no open Safety Recalls or Special Service Campaigns for your vehicle.

But in a post above someone claims the 2011 Tundra is part of the AIPS recall? And no, it does not show my truck as having any work done to repair this issue.

I called Toyota and they said that my truck has not had the AIP replaced but my truck is covered under their "Customer Care Program" so it's not a recall. I have until August 2021 or 150k to get the AIP replaced IF AND ONLY IF, my truck is having problems with the AIP like the OP's truck had. So, basically, if my truck doesn't have any issues, then Toyota is not going to replace anything. If my truck has AIP issues and it's less than 10 years and 150k miles, the dealership will fix the problem.

Here's the thread: https://www.tundras.com/threads/disappointed-tundra-new-owner.46814/page-2#post-1279495

 

We released our GenII units a couple of months ago to cover the FlexFuel and later model years all the way up to current, 2019. The GenII units also cover almost all of the current vehicles we cover with our V36 and V54 units. There are still some 4.7L vehicles we don't cover yet that will require a little more development. You can find our current offering of the GenII kits here: GenII Kits, PSO.
If anyone has any questions about our kits, coverage or codes just let us know. https://hewitt-tech.com
Toll Free 844-307-7671

 

I had the same prob with my 08 CM. I put the bypass kit on. Immediately responded and no more limp mode. All my lights are still on but it performs great. Just got techstream hoping to fix.

 

If you still have lights after install get the codes and let us know what they are. Could be something simple or with the v36 and v54 something like needing a kit addon for as bad pump motor or valve solenoid. The GenII doesn't need those.

 

thank you

 

I have a 2013 with the 4.6. I have just under 88,000 miles. I have not had any AIP issues as of yet, but is it recommended to have a bypass kit on hand or install one now.....or wait until a pump fails? Someone mentioned a mpg gain after install? Thanks.

 

I personally just went ahead and bought the Hewitt bypass kit as prevention. I plan to use this truck for long trips and would rather not have the system crap out on me at an inopportune time.

It also makes it easier if you’re doing this as prevention, since you really don’t have to worry about the exhaust block off plates.

 

I remember having a flash done regarding the AIP on my 2012 5.7 when I bought it 2 years ago with 84K miles. The car fax showed an open campaign so I made them do it before I signed anything. I then remember getting or reading a letter stating that because it is part of emissions it’s covered for something like 10 years from the date that my truck was first on the road (which was 3rd/4th quarter 2011).

 

Plenty of people purchase them as prevention. Any MPG gain from installing one of our kits would be from just getting the vehicle out of limp mode.
While in limp mode the vehicle is just running baseline maps and not relying on the engine sensors to tune the engine resulting in poor power and efficiency.

The open campaign could have been any number of things and that particular flash was not necessarily SAIS related. There were re-flashes to prevent the gas and brake from being pressed at the same time for the runaway throttle issue. If it was re-flashed it was not part of the SAIS warranty extension as that currently only covers replacing parts if they fail. There was a limited service campaign that involved a flash to make the pumps run at shutdown on 12-13 Tundra and Sequoia 5.7L if you took it in with valve stuck closed codes in the freezing weather. That is the only flash we are aware of that has any bearing on the SAIS. If you had that flash you would need one of our Gen-II kits as the V54H cannot prevent the system from running on shutdown.