Concerning finding on my first service visit.....

OK, with that bit of information, 0.001" out of tolerance could make sense.

Tundra Service Repair Manual indicates maximum axle shaft runout as 1.5mm or 0.0591" (nearly 1/16") for the shaft itself. BUT, the maximum allowable on the axle flange is only 0.05mm (0.00197"). "(I)t is out by 1/1000th" means the axle FLANGE has nearly 0.003" TOTAL runout and exceeds Toyota's allowable. The axle shaft should be replaced. Good on Mr. Master Tech.

I would let them do the repair without hesitation. That confirms you've got a good dealer.

 

Perfect; just spoke to the master tech on the way home. He was nice enough to call me to give me an update. A lot of it sounds like Chinese to me but this is the gist.....he said the rear axle shaft is bent. He used a micrometer (I think that’s the tool) and confirmed. Said he has seen this on two Tacoma’s in his time and never on a tundra. It could be related how it was transported. - he said he has never seen one come off the factory line with this. Almost always due to hitting something or some other anomaly. He assured me this was the issue and has no reservation about saying so. Sounded convincing and he was a really nice guy. My buddy told me he is one of the most decorated master mechanics Toyota has in the country as they contact him to determine fixes for issues on a national level apparently.

 

Probably a dial indicator, like this.

 

I wouldn’t be worried about them fixing it at all

 

This is an actual axle flange runout measurement using a dial indicator on Mustang axle flanges. The first reading shows more than 0.010-0.012", and the second reading (other side?) shows MORE THAN 0.022". Toyota's standards (<0.002") are a little tighter.

https://www.youtube.com/watch?v=lTAPRWAE-IU

 

First, the unusual 1/1000th off is a concerning statement from your dealer service. How are they measuring that minute measurement? Also if the axle is truly bent those forces would have caused damage to other components. I would differently get a second opinion.

 

True, out of spec=needs fixed.

Yep, that's how it's done.

See above.
Each tic mark on the dial is .001".

 

Ironically last night took my Tundra in for the 5,000 mile service and they “mistakenly” did a 10,000 mile service and changed the oil. The ironic part was I’d just changed it the day before!

 

My friend at work had his replaced, happened after more miles on the clock then yours but if was fixed and kept on rolling. Btw they had to replace the bearings and axels because he was over loading his tundra saying it's a "heavy half ton" and treated it like a 3/4.

 

Just let them fix it and go from there. They are the professionals, just keep all the documentation for later if need be.

 

Yep, I think this will be my approach. At the end of the day, I know whatever happens my buddy will take care of me. That’s better peace of mind than anything else.

 

What a waste! From now on I will wait until AFTER my 5k services to change the oil!

 

Sorry to hear your troubles, but you are eligible to join the club.

 

Regear it at the same time. If they are already pulling it apart and swapping bearings etc..

 

How are so many people perplexed that someone is able to measure in thousandths of an inch?

 

Tolerance on most automotive parts is between .005 and .008, the confusion is how .001 is critical. Measuring in thousandths is easy to understand, and many even understand the term "Tenth mic".

 

That's not the way I've interpreted some of these comments. Some/most of them obviously are discussing the measurement and how it applies to tolerance, but a few of these sound like they've never heard of a micrometer (not that there's anything wrong with that).

 

My only thought is that if you had hit a pothole hard enough to bend the axle it would be a memorable experience. That would have to be like a 3 bedroom, 2 bath furnished pothole. I sure remember how my axle was dislocated and bent and Im sure I will for a while.

 

There was only confusion about how 0.001" could be relevant when tolerance allowance is typically more than several thousandths on automotive parts. "(I)t was out 1/1000th" was the tech's way of saying the axle flange runout EXCEEDED Toyota's maximum allowance by 0.001".

 

Not on gears:

 

No, but the range or allowed tolerance (backlash) on 3UR differential gears is 0.004"-0.008"..."1/1000th" in that context then makes no sense UNLESS you're measuring 0.009".

The tolerances on the axle bearings will be expressed in tenths of thousandths, and likely not measurable in the field by any means without destroying the bearing.

Edit @computeruser6 : Final finish on precision gears is ground, therefore the tolerances on the gear surfaces themselves is likely in tenths of thousandths.

 

Just perused through here. Seems a bit blown out of proportion. Brand new vehicles often have issues in the first few thousand miles, some small and some major. That's why there's a warranty.

My previous Tundra had an error code for the filler cap leaking at leas than 10k miles. It needed the entire has tank to be replaced because they couldn't separate just the filler neck.

No big deal. I got to drive around in a Corolla loaner for a few days. It was fun ripping around in that thing. Fastest car I've driven, besides all the other rentals I've had.

 

I am very satisfied after talking to the mechanic and my buddy. I think it was more the initial shock of needing such a seemingly major repair on a brand new $40+K truck with absolutely no history of any type of accident, jarring or pothole. I got the truck with 8 miles on it. It will be repaired by an excellent mechanic at a dealership I trust and with people who I know.

 

Update: dealership had Toyota FSE (field service engineer) called in for this. Took my truck, confirmed the issue and replaced the left axle shaft, bearing, etc....no more noise at all. Very happy with the way they took care of me.

 

I am having a similar noise on my Tundra that I was going to mention at my 5,000 mile service. Now I am wandering if I should take it up now and have it inspected.