Help! Rav D4d Transmission Problems

[gringo]

Hi,

I have a 2001 5 door NV 2.0D4D Rav 4 with a mere 42K miles on the clock. For a while now it has seemed a bit noisy particularly at low revs. e.g. 50mph in 5th sounds like you are doing 30mph. It pulls okay but there is a bit of vibration and noise. It then started a higher pitched rattle which sounded like a loose heat shield or something rattling underneath the car. I have a mechanic friend who after discussions with Toyota has diagnosed the Dual mass flywheel as being on the way out. He was told that Toyota have "had issues " with this part. The cost of the part? A totally ludicrous £700. I also have to have the clutch replaced at the same time and hope that when the gearbox is taken out the faulty flywheel has not caused damage inside the gearbox. Anyone else know of any issues concerning this? I reckon I'm looking at a £1500 bill if there is no other damage to the gearbox. A bit dissapointing on a 42K mile Toyota to say the least.

[Turbun]

Gringo

I have a 2000 Avensis 2.0 D4D, 49,000 miles. About a month ago it developed the same symptons as your Rav4. No vibrations but noise just like you describe. Saw bits of swarf falling out of split line betwwen engine and gearbox so decided to remove the gearbox. On doing so found nothing wrong with clutch or gearbox so removed Dual mass Flywheel. The two parts of the flywheel are held together by (I think) 8 Tx40 screws. 2 of these screws had fallen out and the rest were loose. The ones that had fallen out were making the rattle and had caused damaged to the sandwich plate. Was lucky in the respect that I managed to find a replacement flywheel from a car which had only covered a few hundred miles at a cost of £400. This was the only complonent that needed replacing as no damage to gearbox or clutch components was evident. After getting the car back on the road I contacted a few Toyota dealerships and all of them swear they have never heard of this problem. Strange as a quick search on the net showed at least 5 instances of the problem and after reading your post I am convinced this is a major problem for Toyota. After examining the failed flywheel I am of the opinion that the screws came loose only as a result of some other failure within the Flywheel mechanism. This failure resulting in the screws being shocked or vibrated loose. Interesting to note that as far as I am aware most Dual Mass Flywheels have the two parts riveted together and I have never seen a screw set up before.Dual Mass Flywheels have been known to fail on other makes of cars but only after 100k miles or so. Not the 50k these seem to at.Will be very interested to see if you find the same things wrong with yours. Also shop around various dealers when looking for a replacement flywheel as they vary significantly in price. Cheapest I found was around £550. Would not fit a second hand one unless you fiind a very low miler like I did. Good Luck and look forward to hearing what you find.

[gringo]

Gringo

I have a 2000 Avensis 2.0 D4D, 49,000 miles. About a month ago it developed the same symptons as your Rav4. No vibrations but noise just like you describe. Saw bits of swarf falling out of split line betwwen engine and gearbox so decided to remove the gearbox. On doing so found nothing wrong with clutch or gearbox so removed Dual mass Flywheel. The two parts of the flywheel are held together by (I think) 8 Tx40 screws. 2 of these screws had fallen out and the rest were loose. The ones that had fallen out were making the rattle and had caused damaged to the sandwich plate.  Was lucky in the respect that I managed to find a replacement flywheel from a car which had only covered a few hundred miles at a cost of £400. This was the only complonent that needed replacing as no damage to gearbox or clutch components was evident. After getting the car back on the road I contacted a few Toyota dealerships and all of them swear they have never heard of this problem. Strange as a quick search on the net showed at least 5 instances of the problem and after reading your post I am convinced this is a major problem for Toyota. After examining the failed flywheel I am of the opinion that the screws came loose only as a result of some other failure within the Flywheel mechanism. This failure resulting in the screws being shocked or vibrated loose.  Interesting to note that as far as I am aware most Dual Mass Flywheels have the two parts riveted together and I have never seen a screw set up before.Dual Mass Flywheels have been known to fail on other makes of cars but only after 100k miles or so. Not the 50k these seem to at.Will be very interested to see if you find the same things wrong with yours. Also shop around various dealers when looking for a replacement flywheel as they vary significantly in price. Cheapest I found was around £550. Would not fit a second hand one unless you fiind a very low miler like I did. Good Luck and look forward to hearing what you find.

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[Edlo]

-OWN A RAV 4 YOU SHOULD READ THIS AND CONSIDER FUTURE OWNERSHIP-

I have also experienced similar noises on my low mileage 2001 Rav D4D on each occasion the noises dissapeared while investigating where the noise was coming from.

On the last occasion I was fairly certain the noise came from the nearside of the engine but once again the noise cleared and did not happen again during the three week period running up to Xmas, unfortunately on Xmas day during a noise free 3 mile journey the drive suffered loss of drive (no noise, just stopped moving) at about 15mph on an uphill road.

The vehicle was recovered and first checks found all 4 wheels would drive provided they were clear of the ground, the gearbox was removed and examination found the Dual mass flywheel and clutch required renewal.

I am anxiously waiting for confirmation of cost,s.

I would appreciate any suggestions for cause of this failure (could it be prevented)

Is there a possibility of saving the flywheel if the vehicle is taken out of use immediatly the noise is heard or is it to late at this point.

Any suggestions on establishing how many Toyota owners have had to renew this expensive part at low miliage, perhaps any garages who read this could post numbers to this forum.

[shutty]

-OWN A RAV 4 YOU SHOULD READ THIS AND CONSIDER FUTURE OWNERSHIP-

I have also experienced similar noises on my  low mileage 2001 Rav D4D on each occasion the noises dissapeared while investigating where the noise was coming from.

On the last occasion I was fairly certain the noise came from the nearside of the engine but once again the noise cleared and did not happen again during the three week period running up to Xmas, unfortunately on Xmas day during a noise free 3 mile journey the drive suffered loss of drive (no noise, just stopped moving) at about 15mph on an uphill road.

The vehicle was recovered and first checks found all 4 wheels would drive provided they were clear of the ground, the gearbox was removed and examination found the Dual mass flywheel and clutch required renewal.

I am anxiously waiting for confirmation of cost,s.

I would appreciate any suggestions for cause of this failure (could it be prevented)

Is there a possibility of saving the flywheel if the vehicle is taken out of use immediatly the noise is heard or is it to late at this point.

Any suggestions on establishing how many Toyota owners have had to renew this expensive part at low miliage, perhaps any garages who read this could post numbers to this forum.

←

Speak with Toyota customer relations, you may be surprised

[Edlo]

-OWN A RAV 4 YOU SHOULD READ THIS AND CONSIDER FUTURE OWNERSHIP-

I have also experienced similar noises on my  low mileage 2001 Rav D4D on each occasion the noises dissapeared while investigating where the noise was coming from.

On the last occasion I was fairly certain the noise came from the nearside of the engine but once again the noise cleared and did not happen again during the three week period running up to Xmas, unfortunately on Xmas day during a noise free 3 mile journey the drive suffered loss of drive (no noise, just stopped moving) at about 15mph on an uphill road.

The vehicle was recovered and first checks found all 4 wheels would drive provided they were clear of the ground, the gearbox was removed and examination found the Dual mass flywheel and clutch required renewal.

I am anxiously waiting for confirmation of cost,s.

I would appreciate any suggestions for cause of this failure (could it be prevented)

Is there a possibility of saving the flywheel if the vehicle is taken out of use immediatly the noise is heard or is it to late at this point.

Any suggestions on establishing how many Toyota owners have had to renew this expensive part at low miliage, perhaps any garages who read this could post numbers to this forum.

←

Speak with Toyota customer relations, you may be surprised

←

[Edlo]

Thanks for your responce shutty.

What,s the best way to contact "Toyota customer relations"

[Robert John Wesley Cummins]

-OWN A RAV 4 YOU SHOULD READ THIS AND CONSIDER FUTURE OWNERSHIP-

I have also experienced similar noises on my  low mileage 2001 Rav D4D on each occasion the noises dissapeared while investigating where the noise was coming from.

On the last occasion I was fairly certain the noise came from the nearside of the engine but once again the noise cleared and did not happen again during the three week period running up to Xmas, unfortunately on Xmas day during a noise free 3 mile journey the drive suffered loss of drive (no noise, just stopped moving) at about 15mph on an uphill road.

The vehicle was recovered and first checks found all 4 wheels would drive provided they were clear of the ground, the gearbox was removed and examination found the Dual mass flywheel and clutch required renewal.

I am anxiously waiting for confirmation of cost,s.

I would appreciate any suggestions for cause of this failure (could it be prevented)

Is there a possibility of saving the flywheel if the vehicle is taken out of use immediatly the noise is heard or is it to late at this point.

Any suggestions on establishing how many Toyota owners have had to renew this expensive part at low miliage, perhaps any garages who read this could post numbers to this forum.

←

Speak with Toyota customer relations, you may be surprised

←

[Elizabeth McCullagh]

We had a similar problem, see 2RAV 4 D4d Transmission Problem" below. We have exchanged 3 letters with Toyota Customer Servives in Epsom, we were told that the breakdown was Fair Wear and Tear and given a £200 Voucher for Goodwill. We are consedering our next move as having to replace a fly wheel etc at 36000 miles is unprecedented.

[shutty]

ask your dealer to submit a prior authority repair (PARF) to warranty

[diffman]

Transit vans & LTI london taxis also have a dual mass flywheel. It's very common for them to fail at 35000 miles or so(6 months in a taxi) & the part cost £300, smooth gear changes from new is a cheaper option? also there is a conversion back to a solid flywheel, I doubt Toyota will convert back to one piece flywheel as duel mass flywheel's are there to protect the transmission system.

[helipadhead]

GOOD NEWS

Thanks to this forum I managed to diagnose the failure of the dual mass flywheel in our four year old 52 plate, 36000 mile D4D. Our local dealer confirmed the fault when the car was serviced and advised that the clutch and freewheel needed replacement. They also said that it would be in the order of £1500 to£1600 but would see if Toyota UK would help or bear the whole cost - given that the car was of low milage, age and that it had always been serviced by Toyota. Within a couple of days we were advised by the garage that Toyota had a recall with regards to this failure and the clutch and dual mass flywheel would be replaced free of charge.

We have today collected our RAV after the two day replacement of these parts. Toyota have fitted a revised flywheel (it has a new part number) and a new clutch - waranteed for 3 years.

The car is now notably different - smoother when pulling away, no horrible squeeling noise or grunting at max power and the engine vibration we had become used to is no longer present.