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Gearbox design flaw in Yaris (>2006) - pete-woods
My girlfriend bought a brand new 56 plate Yaris from Toyota back in 2006. The gear change has always been a bit crappy, but then about 6 months ago the gearbox started leaking oil.

Still being under warranty, we took it into the Toyota shop and they 'repaired' it. The gearbox stopped leaking, but now the gear change into first and second was _very_ poor.

Being a bit upset with this my girlfriend took in back into Toyota. They had an 'engineer' drive it who said that it was the best gear change in any Yaris he'd ever driven. Girlfriend was understandably upset at this blatant lie and eventually kicked up enough of a fuss to get them to replace the clearly screwed gearbox.

After nearly a month in the garage they 'replaced' the gearbox. At least they said they did. They haven't really. They've just replaced the alignment rings. I'm confident about this because they won't give us any paperwork showing that a new gearbox has been put in.

I'm also confident about it because the gear change is now awful. It's extremely difficult to get the car to go into first unless you wait quite a while for the oil to warm up.

After some more fun, Toyota have now admitted that there is a design flaw on the Yaris that makes the gearboxes behave this way. They say they can't fix it because the replacement gearbox hasn't been designed yet, so we should wait a few years (!!!!!).

When she asked what they could do about it now, they said:
* They'd take the old one off her hands for £3500 (it was £10500 two years ago)
* She could buy another one (she was very amused by this I can assure you) and they might consider offering her more money

Taking it to a Peugeot dealer we asked what they'd give us part-ex and they offered £4700.

If other people have had a similar experience I'd be interested to hear. Also if anyone has advice on what the hell to do really.

Edited by Dynamic Dave on 22/10/2008 at 19:30

Gearbox design flaw in Yaris (>2006) - nortones2
For clarification PW, when you say Toyota "engineer" and the comment re "design flaw", do you mean the dealer staff, or have you been able to get Toyota HQ personnel involved? Reason for asking, is that wife had a gearbox driveshaft seal fail repeatedly when we had a Yaris. Fobbed off by the dealer, eventually resolved through contact with Toyota customer support, and the Toyota (GB) Technical department, after writing to the dealer and to Toyota (GB).
Gearbox design flaw in Yaris (>2006) - Bill Payer
Are you dealing with the dealer who supplied the car new?

Not sure you'd get anywhere if push came to shove but might be worth gently suggesting to them that, as it is, the car isn't "fit for purpose", and how do they intend to rectify that situation.

I don't think you should go as far as to threaten them, or they might throw the shutters up and call your bluff.
Gearbox design flaw in Yaris (>2006) - pete-woods
Unfortunately we're not dealing with the original dealer. We've moved a considerable distance from them now.
Gearbox design flaw in Yaris (>2006) - pete-woods
The "Engineer" wasn't from Toyota HQ, but since that Toyota HQ have been involved. They are the ones who said the the problem was a design flaw.
Gearbox design flaw in Yaris (>2006) - jc2
A "fitter" or more likely an "apprentice".
Gearbox design flaw in Yaris (>2006) - nortones2
Is this comment re design in writing? I'm sure VOSA would be interested......
Gearbox design flaw in Yaris (>2006) - Avant
"After some more fun, Toyota have now admitted that there is a design flaw on the Yaris that makes the gearboxes behave this way."

I'm afraid that's a lie. They aren't all like that: elder daughter has had three Yarises, that last two Mark 2s, and the gearchanges are excellent. A second opinion is needed; most Toyota dealers are pretty good, notably our local one, Octagon Bracknell.

There is something wrong with it and Toyota and/or the dealer must be made to put it right or preferably replace the gearbox.

Edited by Avant on 22/10/2008 at 21:08

Gearbox design flaw in Yaris (>2006) - madf
If the dealer is a Toyota one, Toyota will be most upset. You shoudl write to Toyota UK detailing story and what you have been told...

Toyota will NOT be amused at the lies given.. and you should get quick redress.
Gearbox design flaw in Yaris (>2006) - oldnotbold
Sounds like a great story for Watchdog on the BBC....
Gearbox design flaw in Yaris (>2006) - DP
Well, if you're relying on Toyota GB for help, I just hope they've got their act together since my friend was dealing with them back in 2002/3 for persistent faults on his 51 reg Celica 190. If it weren't for the dealer bending over backwards, he would have been driven to despair.

There was a whole list of woes, but this one sums it up. The gearbox stuck in 4th at 1500 miles. Dealer strips the box and finds no trace of a very important circlip. This has led to significant other damage with dozens of new parts needed. Dealer assumes they'll just fit a new gearbox which they can have next day and fit the day after. When they go to order it, Toyota refuse. They insist the dealer rebuild the old gearbox and refit it, despite the estimated ten day wait involved. This is on a 1500 mile car with a build fault! This was just one thing - there were endless other problems which culminated in a cancellation of the finance agreement at 18 months, and dumping of the car outside the dealership.

I wouldn't have believed it if it hadn't happened to a good friend in front of my own eyes.

Cheers
DP


Edited by DP on 23/10/2008 at 14:15

Gearbox design flaw in Yaris (>2006) - pete-woods
The worry I have is that it's now Toyota HQ that are dealing with the case. They are the ones saying that a new gearbox won't help and that all we can do is wait til they design a replacement.
Gearbox design flaw in Yaris (>2006) - Gerry Nimmo
Is this related to the clutch judder that Toyota now seem to regard as normal? Every manual Yaris I've driven has had an imperfect clutch, some much worse than others.

The other thing is I wonder if this is related to the strange idea of having to hold the clutch down while the car is started?
Gearbox design flaw in Yaris (>2006) - Lygonos
>>The other thing is I wonder if this is related to the strange idea of having to hold the clutch down while the car is started<<

To be fair, this is actually recommended by many manufacturers and also motoring organisations. Holding down the clutch while starting the car reduces drag on the engine as it isn't spinning the clutch/drive mechanism. This slightly helps starting and reduces wear on starter/engine parts.

I believe Hyundais have a switch that prevents you starting it without depressing the clutch.