Avensis D4d Clutch

[Call me Ishmael]

Hi Folks,

I've got a 2004 D4D with 75,000 miles on the clock. I've just noticed what appears to be a slipping clutch. It doesn't happen all the time and generally starts around 2,000rpm in top gear with hard acceleration.

The engine will rev up to about 2,500-2,800rpm, with the clutch fully engaged, for no apparent increase in speed. Then it settles again as if taking up the drive once more. It seems to be at its worst just after changing up into top gear, as if I'm still 'riding' the clutch when really my foot's clear of the pedal.

Given the mileage, do you think the clutch is on its way out or could the dual mass flywheel be at fault?

I get the car serviced at an independant Toyota specialist, as opposed to an official dealer. What can I expect to pay if he needs to replace the clutch and/or DMF using genuine Toyota parts?

Any help much appreciated.

[RK123456]

Hi.

I had a 2006 D4D as a company car. The clutch had to be replaced at approx 70k miles so you're not alone.

[JohnYossarian]

Hi.

I had a 2006 D4D as a company car. The clutch had to be replaced at approx 70k miles so you're not alone.

I did change mine including fly wheel when it had ca. 70000 miles on the clock.

[Call me Ishmael]

Thanks guys.

Dare I ask roughly how much the whole job cost, including labour, clutch and replacement flywheel?

[JohnYossarian]

Thanks guys.

Dare I ask roughly how much the whole job cost, including labour, clutch and replacement flywheel?

I paid about £ 900 (including a master cylinder replacement at £120). The main cost is labour, 6.5 hours. At Toyota this comes to almost £ 500. The cost of the parts is not that prohibitive.

The fly wheel was not changed but my Toyota dealer (after the clutch was changed I experienced exactly the same problem, impossible to shift gears) replaced the fly wheel for free afterwards. I was very impressed. I have come across quotations between £1200 to £1500 for clutch and flywheel all together. I guess in a decent garage you can cut deal provided you trust the guys.

I preferred Toyota as the clutch comes with three years warranty, with a garage you would get one year only.

Good luck!

[Call me Ishmael]

Well I took the plunge and called in with the independant Toyota specialist that services the car. He took the car for a test drive and confirmed what I had suspected - the clutch is slipping and adjustment won't cure it.

He'll change the clutch and the dual mass flywheel (replacing it with a solid one), using genuine Toyota parts, for £750+VAT.

Does that sound ok or am I being ripped off?

I'm intending to hold onto the car as long as possible, at least another 5-6 years or until it's completely worn out, hence the reason for wanting a proper flywheel.

[JohnYossarian]

Well I took the plunge and called in with the independant Toyota specialist that services the car. He took the car for a test drive and confirmed what I had suspected - the clutch is slipping and adjustment won't cure it.

He'll change the clutch and the dual mass flywheel (replacing it with a solid one), using genuine Toyota parts, for £750+VAT.

Does that sound ok or am I being ripped off?

I'm intending to hold onto the car as long as possible, at least another 5-6 years or until it's completely worn out, hence the reason for wanting a proper flywheel.

As long as he is a reliable guy the price given is fantastic for a clutch and a fly wheel (provided they are genuine). But see what other people have to say.

[Call me Ishmael]

Hi John,

That's a fair comment about the reliability of the garage. I know there are lots of cut-price cowboys (as well as some high price cowboys!) out there, but I think these guys are sound enough. It's a small family-run business that's been dealing in Toyota for years.

I'll let you know how I get on.

Thanks for your help.

[t-spiritpete]

Hi John,

That's a fair comment about the reliability of the garage. I know there are lots of cut-price cowboys (as well as some high price cowboys!) out there, but I think these guys are sound enough. It's a small family-run business that's been dealing in Toyota for years.

I'll let you know how I get on.

Thanks for your help.

Hi Ishmael, there is a new problem created after fitting a solid flywheel/clutch assembly. Because of the power and frequency delivered by a diesel engine a very low revs you can damage the gearbox over time. The way for you to get round this is to use the gearbox more than before, keep the revs higher, don't let the engine labour under load and you should be fine.

Best regards Pete.

[Beagh1958]

Sounds like a great price. But as to parts, are you sure your man is fitting genuine Toyota clutch kit & flywheel. Or just a genuine Toyota clutch with another brand solid flywheel.

Regards, Beagh.

[Call me Ishmael]

Thanks for those tips guys. Sorry it's taken me so long to get back to you, things have been a bit hectic this weekend.

I agree with you Pete, any jerky movement in the engine will be transmitted into the gearbox without the cushioning effect of the DMF. It'll just be a case of adjusting driving style to avoid that. Mind you, my wife drives the car 90% of the time and she's a bit heavier on the throttle than I would be, so there shouldn't be a problem!

Beagh, I've checked with the garage and it's all genuine Toyota parts (both flywheel and clutch kit) that they'll be fitting, which I'm happy with.

Anyway, the car goes in on Tuesday this week and it's going to be a long time to pay day!

[aplanterose]

Mine (2.2 D4D Avensis Tourer) had a clutch that slipped and juddered at random. Big fight with Toyota about me "abusing" it - turned out gearbox oil seal had failed and they finally covered the cost. This was two years ago at about 40K miles. Engine has been out twice since then (for two replacements, since the first fresh recon from Toyota ripped the crank to pieces when it was first started) about a year ago. Various electrical problems too.

I do not thrash my car in the slightest.

Toyota HQ take the view that they have paid for it all (except the electrics), so where's my problem?

Does one day a fortnight off the road for repairs sound OK?

Don't even think about asking me what I think about Toyota "Quality"?

The dealer is brilliant - I just wish I didn't have to visit so often.

[toymotorowner]

It looks like the clutches on the D4D Avensis is becoming a problem. I have an 07 2000 d4d with just under 20,000 miles on the clock and.... yes you've guessed, my clutch is slipping, well I say slipping judging by the smell that is coming from it after a run. I have been in the auto trade for some 40 years and although now semi retired I have never driven with my foot on the clutch pedal and do not hold it on the clutch on hills etc. (my last car, a Ford I only managed to get 90,000 miles out of it before replacement). I now have the task of taking the car to my local Toyota dealer in the hope that something is done about it. The unfortunate thing is that my warranty ran out in June so I really don't know what to expect from them yet. I do expect a problem with Toyota as I have a tow bar fitted and this I can see they will use as a get out, although it has only ever pulled a small trailer for the odd trip to the tip. Fingers crossed.

[revpermin]

Hi. My 2003 d4d Avensis has covered 175,000 miles on the same clutch, it started to slip a bit 2 years ogo so now looking at replacing with a solid flywheel one.

To get one go at 20,000 miles is bad luck. I have heard that this is the weakest link in the d4d's armour!

when I first got mine it had 7,000 miles on it & I drive it mainly short distances. it used to blow bulbs every month, got angry & pulled the starboard side wiring loom away from the front inner wing, no more blown bulbs, air con compressor failed at 80,000, £600 to fix so put a shorter belt on it missing out the comp pulley, I replace front wheel bearings every 50,000 or so.

I change the oil etc, every 10,000 using full synthetic racing spec oil.

Every thing else is as you'de expect for any car. I have to say it's the most cramped car to work on i've ever had but it's never left me stranded !!

Phill

[frankie406]

Mine went at 70k too.replaced with smf and clutch.changed it not long ago around 92k to dual mass again as the 3rd gear started to grind..do Toyota do a solid kit??

[Milky Bar Kid 1001]

So is it better then to buy a new DMF when replacing the clutch or is the swap to a solid mass a better option? To be honest if swapping to a Solid will damage the gearbox over time then I'd rather stick with a DMF. What are peoples thoughts on this?

[Milky Bar Kid 1001]

Really confused now as to what to do when I change my clutch. Mines on 115,550 miles and as far as I know is the original (I bought it with 73,000 miles). I'm on top of all maintenance and service it every 10k. I don't drive like a nutter (not really possible in a 127bhp diesel tourer!! Lol) either.