Bad Gear Selection

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Hi, We were ever-so pleased with our previous Rav4 that we had for three years from new that we decided to purchase another brand new Toyota Rav4 XTR in Sept 09. Now with only 6500mls on the clock things are not as they should be. We were more than please with our purchase until approx- 2/3 months ago, when we both noticed that things weren’t feeling as good as they did when we first bought the car. We both noticed the gear selection from 1-2nd was getting very clunky, but intermittent! The car also shudders or shakes around 2000rpm. This is worse from time to time. There has also been 3-4 occasions when we have pulled up to either park or stop the car (idling) that the engine was much louder than normal, making a chattering noise (similar to an old engine with off-set tappets but worse) the car was also shaking at this time. When this has happened I've switched off the engine and restarted it. The engine has then gone back to normal idling. My wife has also experienced a dead spot or jolt while cruising at a steady speed on a motorway.

Since these problems were reported to Toyota (Minories) our car has been in for repair. They say they have replaced the clutch and fly wheel. This has made no difference what-so ever in fact its worse. The 1st-2nd gear selection is still clunking, also its more difficult (stiff) to get out of 1st gear and reselect 1st gear, more-so when the engine is still cold.

Monday gone (22/11/10) we returned to the dealer for another test run. but also to say we have noticed a burning smell which is quite strong. The smell only lasts for max- a minute! We have noticed this smell on numerous occasions in the past couple of months but having leather seats we just thought it was the heated seats until last week when we didn't have them switched on.

Our car is going back in next week for repair again, but we are not sure if they know what they are looking for.

Does any one have any ideas or advice?