New Clutch?

[aygo_gemma]

Hi there, I have a 55 plate Aygo plus model, i've had it for 2 years, currently at 28'000miles, not had any "big" bother with it until Friday...

The gears stopped working, total struggle to get it into any gear and it totally limped along the road. When I eventually force it into gear, it crunches and rattles etc. I got my car recovered to the nearest Toyota dealer thinking that was my best option as they are "experts" in toyota cars and wouldnt just automatically replace the clutch. The recovery mechanic believes the issue is with the clutch cable and not with the actual clutch but Toyota phoned me today and said that its going to cost me in the region of £545 to get the clutch replaced and they believe the clutch is damaged.

Not the best news i've had given that my car isnt that old. Gutted that the warranty expired in November 2008. Also, my brakes were squeaking last year and after a 15minute check of my car, Toyota said they needed replaced, so me believing them, let them and they charged me £89. I'm now wondering if Toyota are "at it" and just replacing things to get more money.

The good news is, i've managed to get a local garage to recover my car to their premises and they quoted me £390 to recover it and replace the clutch (if required) all inclusive. So i'm guna save a fair bit of dosh but just wondered if anyone has had the same problem? If anyone thinks it could be an issue with the cable or if it sounds like the clutch is totally gone?

Also advice on the price and if you think i'm being done or not bad quotes?

Cheers

Gemma

[zakelwe]

Hi Gemma,

Sorry to hear of your woes. Not sure what you mean when you say the brakes needing replaced, so you mean discs or pads? Or both?

I don't think Toyota are making it up, both clutch and brake discs seem a weak spot for Aygo's and other people have reported similar issues. The cost is OK for Toyota but you will be able to get it cheaper as you found out. Sad thing is you might only get another 20 000 + miles out of it before it goes again. There are threads on here about fitting the Yaris clutch which is more beefy, you could try this approach. My Yaris clutch lasted 90 000 miles before wearing out and that was going 60 miles per day into the West End of London! I did 4 zillion gear changes over that time.

I've decided to junk my brake pads and discs this month for EBC discs and greenstuff pads. It will stop the graunching and give a lot better performance. Why wait for them to screw up, might as well sort it out now and enjoy the benefits.....

Good luck.

Regards

Andy

[aygo_gemma]

Hi Andy,

Thanks for your reply. I needed the full works replaced - the brakes and brake pads. The brakes were covered under warranty but I had to pay for the new brake pads plus labour.

Its a bit alarming that i'll need to get a new clutch in another couple of years. I thought Toyota's are meant to be reliable cars?? Is it because the Aygo is more cheaply made and because of the links with Peugeot and Citreon? One of the main reasons I got a Toyota Aygo is because I thought it would last longer than alot of other city cars out there. Is it expensive to get a Yaris clutch for my car? Something I never even thought about.

Cheers

Gemma

Hi Gemma,

Sorry to hear of your woes. Not sure what you mean when you say the brakes needing replaced, so you mean discs or pads? Or both?

I don't think Toyota are making it up, both clutch and brake discs seem a weak spot for Aygo's and other people have reported similar issues. The cost is OK for Toyota but you will be able to get it cheaper as you found out. Sad thing is you might only get another 20 000 + miles out of it before it goes again. There are threads on here about fitting the Yaris clutch which is more beefy, you could try this approach. My Yaris clutch lasted 90 000 miles before wearing out and that was going 60 miles per day into the West End of London! I did 4 zillion gear changes over that time.

I've decided to junk my brake pads and discs this month for EBC discs and greenstuff pads. It will stop the graunching and give a lot better performance. Why wait for them to screw up, might as well sort it out now and enjoy the benefits.....

Good luck.

Regards

Andy

[C_U_Jimi]

Hi Gemma,

I bought my Aygo thinking that the engine and gearbox were Toyota units and the rest of the car part Peugeot and part Citroen. I've since found out that the engine and gearbox are actually Dhaihatsu units albeit 'improved' by Toyota. So what we actually have is an amalgam of Dhaihatsu, Peugeot and Citroen engineering.

At 25000 miles my engine is now showing signs of internal mechanical problems. My previous car was an early version of the Yaris and covered 95000+ miles without a single problem. I passed it on to my son who has used it for a year now without any problems. I seriously doubt that the Aygo will last as long. Some people seem to think that I am expecting too much from a budget car but I maintain that they should last longer than people are reporting on this forum.

Just a thought but you could take your Aygo to a Citroen or Peugeot dealer who would probably charge less for parts than Toyota. The Citroen C1 and Peugeot 107 are mechanically identical to the Aygo. The three cars only have different front and rear modules.

[adilmon]

Toyota have had an issue with clutch cable adjustments on some Aygos and published a service bulletin to correct this. It's possible that your rapid clutch wear happened in this interim period, before it returned to the garage to be correctly adjusted.

If it were me I would complain and say that there should have been an immediate recall (for checking) as soon as service bulletin CP-8016 was issued in October 2008.

If your Aygo has been into a toyota garage for servicing since 10/2008, you have nothing to argue over. This service bulletin is "necessary to ensure maximum clutch disc lifetime for cable type clutch systems"

You're right about going to Citroen or peugeot (PSA) for better value servicing. Toyota designed and managed the Aygo/C1/peugeot car platform, and PSA supplied the diesel engine, logistical support for european manufacturing, designed their own front & rear ends and shared the development costs. The Aygo petrol engine can be found in a daihatsu (Toyota owned), but without the VVTi system.

[Rotten Ali]

Reporting that I had a clutch fault repaired too. Mine went at 24,100 miles with only a few miles warning (just the hint of the clutch slipping) prior to the drivetrain packing up and going on strike! Thankfully it was still under the 3 year parts cover.

[Donna_Aygo]

I had my clutch replaced 2 months ago at 30,000 miles and they put the Yaris clutch in. It was not slipping but was making a slight creaky wierd noise in 1st and 2nd gears and they told me taht they know about this fault but only do something about it if the customer picks it up and complains. I did not complain I just told then to check this noise which they were good to admit to it. I must say that I am very impressed by the level of service offered by my local Toyota dealer as they are a joy to go to with excellent coffee too!!!

[johnan]

I had my clutch replaced 2 months ago at 30,000 miles and they put the Yaris clutch in. It was not slipping but was making a slight creaky wierd noise in 1st and 2nd gears and they told me taht they know about this fault but only do something about it if the customer picks it up and complains. I did not complain I just told then to check this noise which they were good to admit to it. I must say that I am very impressed by the level of service offered by my local Toyota dealer as they are a joy to go to with excellent coffee too!!!

I live in Fife (also in sort of central Scotland) Donna, who is your local dealer, or at least what town, if I may ask?

Sounds like a good-un!

EDit:Just read your post in the "brakes" thread and you mention Falkirk, so, question answered!

[Donna_Aygo]

Hi, I live in Falkirk and the Toyota garage at Square Deal Motors seem fair. Although I think my exhaust has been a bit blowy since I got her and I keep asking them to check it as I am hoping for a new one under warranty :D

[robers7]

Sorry to resurrect an old thread, but do you have the full document for the service bulletin CP-8016 you quote?

It looks like my clutch has had it at 33,000 - an unreasonably short life on most cars. To attempt a warranty claim it needs to be with a main dealer so you are kind of over a barrel if they conclude its not a warranty job. I'm hoping the service bulletin would help.

Thx

Toyota have had an issue with clutch cable adjustments on some Aygos and published a service bulletin to correct this. It's possible that your rapid clutch wear happened in this interim period, before it returned to the garage to be correctly adjusted.

If it were me I would complain and say that there should have been an immediate recall (for checking) as soon as service bulletin CP-8016 was issued in October 2008.

If your Aygo has been into a toyota garage for servicing since 10/2008, you have nothing to argue over. This service bulletin is "necessary to ensure maximum clutch disc lifetime for cable type clutch systems"

You're right about going to Citroen or peugeot (PSA) for better value servicing. Toyota designed and managed the Aygo/C1/peugeot car platform, and PSA supplied the diesel engine, logistical support for european manufacturing, designed their own front & rear ends and shared the development costs. The Aygo petrol engine can be found in a daihatsu (Toyota owned), but without the VVTi system.

[Projectzip]

anyone know which Yaris clutch you need?

[robers7]

anyone know which Yaris clutch you need?

OK - I worked this out. Technical Service Bulletins are available from Toyota Tech at www.toyota-tech.eu - for a cost (3€ buys you 1 hour to download as much as you like).

Regarding the clutch, TSB CP-8016 is actually a clutch adjustment bulletin to ensure there is good free-play in the clutch pedal. Apparently, a lack of free play leads to excessive wear of the clutch disc. This was published in October 2008 and was supposed to be implemented as a pre-delivery check for new cars and at each regular service interval.

A further TSB CP-8007 (published June 2008) acknowledges customer's concerned about premature clutch wear. The repair procedure described is to replace the clutch disc and cover assemblies with those used on Yaris KSP90. Notably, the clutch engagement point will be about 2cm lower than the standard Aygo clutch.

Also, in December 2008, TSB CP-0067 was published summarising symptoms including: slipping clutch; abnormal smell; premature wear of clutch disc; and squeal noises from the clutch during stop and go. In terms of early wear, CP-0067 describes the clutch pedal free-play issue and further considers the materials used in the clutch cover and disc. To address early wear, CP-0067 mainly recommends checking the pedal free-play. There is also a production change in this bulletin to a 7.5inch clutch discs and covers (from 7inch) - likely to address a resonance issue causing squeal noise in the clutch.

In view of this material, it seems to me there is a design fault (and consequential manufacturing fault) in the Aygo clutch for vehicles produced at least before June 2008 and possibly later. Early wear of the clutch disc is therefore to be expected for these vehicles and they should have been recalled. Costs incurred replacing clutch discs suffering premature wear should be borne, at least in part, by Toyota in view of the fault.

[Projectzip]

Thanks bud I shall furnish my garage with this information should my Warranty Clutch not be covered!

[geezbeez]

Costs incurred replacing clutch discs suffering premature wear should be borne, at least in part, by Toyota in view of the fault.

I wonder how the terms are for garages on such things. I imagine they claim from Toyota albeit at some capped rate so are not out of pocket them selves?

Obvously effects thier willingness and enthusaism to perform the repairs.

[ect76]

Costs incurred replacing clutch discs suffering premature wear should be borne, at least in part, by Toyota in view of the fault.

Hi All.

My Aygo Black is now out of warranty. The clutch has been making that squeaking noise when moving off since before the warranty ran out, and it's now started to judder a bit when moving off. Is my clutch long for this world? If so, the full cost is my responsibility isn't it as it's out of warranty? Would I have any case to argue in view of the TSBs?

EDIT - Forgot to mention I'm only at 33k miles on a 56 plate.

[Pinturicchio]

I've got a 55 plate and done about 55,000 miles and no problems with my clutch so far. How about everyone else?

I have had my brakes done a year or two ago, however.

Remember, just because they've quoted you doesn't mean that you have to buy!

Buy all means shop about and get the best price.

[Pinturicchio]

Hi, I live in Falkirk and the Toyota garage at Square Deal Motors seem fair. Although I think my exhaust has been a bit blowy since I got her and I keep asking them to check it as I am hoping for a new one under warranty :D

I live in Falkirk too btw : )

Or should that be a : ( haha

[Dylan1]

My wife has a 56 plate Aygo Sport.

Clutch gone at 31,000 miles.

New discs/pads required at first MOT, shocking!

Wrote a letter of disappointment to Toyota, but did not get much sympathy there regarding the clutch.

A friend works in a Peugeot dealer and they seem to have lots of 107's in with the same problem's.

As we took out the service plan, the main dealer did a deal to replace the clutch for £460, instead of the retail £560 odd!

Still, a shocking amount of money for what is supposed to be a budget car! 1/15th of the price of the car!

First ever Toyota and it will be the last.

I think that everybody that has the clutch problem should write to Toyota anyway, just to register your disappointment with the quality of the brand.

[musicegbdf]

I persuaded my daughter to buy new Aygo , because it was a Toyota and will be reliable !!!

She was 18 , and this was a brand new car for her. It has always been serviced by local Toyota dealer (she has a service plan with them) , and she has Toyota assist. She is now 21 and the car is 3 years and four weeks old.

On sunday the clutch stopped working. If you depressed the pedal in neutral with the engine running there is a loud clunking noise. Raise the pedal and it goes away. Put it in gear , not problem with the biting point , but it is almost impossible to get into gear.

Toyota assist arrive (AA ) and agree there is something seriously wrong and must goes straight to dealership.

We get a call , the clutch has gone , we want £680 !! a lot for me let a lone a student/ part time waitress.

So dad gets involved. I challenged the garage that a local clutch specialist charges £325 , but that I had googled and found a number of problems reported between 25,000 and 30,000 miles (my daughter has 32,000).

They admitted there has been a fault , but they could not check this until the gearbox had been dropped and the clutch checked. Apparently there are studs on the housing that shear off(?) I managed to get them to reduce the price to £570 on the basis if they found this fault they would contact Toyota and see what can be done. Sure enough this morning they confirm this was the fault and even though out of warranty Toyota will contribute and the cost is now £260..Ok a result , but I still do not see why she has to pay anything for something that is clearly a design fault.

With the poor reputation Toyota are developing can they afford to lose a 21 year old , that expects to be buying a new car every 4/5 years. I currently drive a Honda CRV and was looking to change sometime soon , and did consider a Rav 4....not now.

I will be writing to Toyota...or maybe even watchdog !!

UPDATE

Now it is difficult to select 2nd gear , I wonder if the gearbox has now got some damage due to the problem..!

[Smoothound]

57 Aygo Blue

49000 Miles

Hence : Still In Warranty (JUST!)

I have the clutch judder problem too.

I first noticed it at the last service 40,000, but I thought it was engine related and would go away once the air filter had been replaced. It didn't go away so I thought I'd raise it this time round. The dealer are not (at this point) acknowledging any known issues with the Aygo clutch, although they admit the clutch has been revised. It's going in next Weds for an inspection, but I have a feeling that the dealer are going to try and bill me for it. Will keep you posted.

[dotbit]

I have an 2007 Aygo with the 1KR-FE (1l petrol) engine and the 5 gear MMT clutch at 120000 km (~75000 miles).

Had break discs become crooked, requiring replacement. I am now have a second slipping clutch, the first one was replaced on warranty. Shall check with the local Toyota dealer.

Actually I should also check how the (automatic) MMT gearbox handles driving slower than ~900RPM at first gear in traffic jams. Sometimes if I break while being bellow this motorspeed it feels like both the clutch and breaks are wearing at the same time.