Whining noise from driver's side

Just to give you guys an update of my 04's continuing problem here's what's happening.

The electric motor seems to be straining to get the car moving. The ICE has to kick in way sooner than normal to accelerate. The car acts like it has those big mud bogging tires with the big lugs. You can feel the lugs (or gear teeth) lugging. Don't know how else to describe it. The traction battery is staying highly charged (in the green). The gas mileage is much lower than normal.

There are still no codes or lights. I keep the scan gauge on all the time.
Any ideas. Thanks, Ron

 

Hi again Patrick:
I couldn't stand not knowing the problem so I took it to Toyota today. Three mechanics drove the car with their scan tool. Then they ran the car on the rack with the ICE disabled. They pin pointed the noise to the transaxle and said it is not long in this world.

When they ran it after disabling the ICE many lights and codes appeared that did not register on my scan gauge. Their opinion is that the differential carrier bearing or the pinion bearing are failing.

This is the first example of transaxle failure this Toyota service dept. has seen. It is truely a rare occurance. Like winning the lottery.

I already have a salvage transaxle from an '05 with 40k miles on the way. I have all the Toyota maint manuals and a shop garage. I will attempt to change it out myself. If you have any pointers let me know. Thanks, Ron

 

Hi Patrick:
Thanks for the suggestions. I started tearing down the car today. I should have the transaxle out tomorrow. The salvage unit should arrive in 4 or 5 days. I may end up replacing one or both drive shafts. The wheel bearings show no signs of wear (play or noise). I'm not removing the engine and it seems to run well with no oil consumption between changes @ 7000 miles.

The Toyota dealer quoted a price of over $6,000 to replace with a new unit. They would not consider installing a used one. All said and done I should have it done for under $1000. I will keep you posted, Ron

 

Patrick:
I will try to get some photos posted with my teenage sons help as time permits. I am not very computer savy.

Didn't get the transaxle removed yet but this will be the next step Monday morning.

Ron

 

The transaxle is out!
Now the hard part (taking out is always easier than putting back). After the replacement arrives and my car is running, I will tear the old unit down to see what failed. I will try to take pickures and keep you informed.

 

I finished the installation of the 05 transaxle into my 2004 today along with a low milage drive shaft on the driver's side.

The car drives well with no unusual noise . I found the toyota manual to be very helpful. I did do things a little out of order to make things easier.

The most difficult part was disconnecting some of the plugs that were very hard to get to. Also the drive shaft on the driver's side refused to come out no matter how hard I tried. It took much patience and three different jacks and hoists to align and install the new transaxle into the engine.

I got the transaxle and drive shaft from Hybrid Autoparts in Rancho Cordova, CA. They were very helpful and reasonable.

I leave on a 4 day trip tonight but when I have some time I hope to tear down the bad transaxle and determine what went wrong and why. I might even have pictures.

Thanks everyone for your input.
Ron

 

Hi Patrick:
The three vol. Toyota manual I referenced did not suggest removing both the engine and trasaxle as a unit. But it probably would have been easier in the long run to have done so.

If I ever do this again ,(and I hope I don't), I will probably do both at the same time. Dispite all the pain and agony I appreciate the experience for what I have learned.
Ron

 

Hi Patrick:
I didn't punch a time clock but I estimate approx. 20 hours work. Thankfully I was on vacation.