NHTSA Complaint #10244728 — 2002 TOYOTA RAV4

OUR RAV4 BEGAN TO HAVE PROBLEMS SHIFTING, AND THE CHECK ENGINE LIGHT WAS ON. TOOK TO LOCAL DEALER. FIRST VISIT RESULTED IN TUNE-UP ITEMS. DEALERSHIP TREATED IT AS AN ENGINE-RELATED PROBLEM. CHECK ENGINE CAME BACK ON AGAIN THE SAME AFTERNOON. ON SECOND VISIT, DEALERSHIP KEPT CAR OVERNIGHT TO DRIVE IT WHILE IT WAS COLD. WE WERE TOLD THAT WE HAD A BAD CATALYTIC CONVERTER, AND THAT THIS WOULD HAVE TO BE REPLACED BEFORE ANY FURTHER DIAGNOSIS COULD OCCUR. THE CC WAS ONLY THREE YEARS OLD, ALREADY HAVING BEEN REPLACED UNDER WARRANTY. THEY HAD ALREADY REPROGRAMMED THE ECM. PER A TOYOTA SERVICE CAMPAIGN. AFTER THE CC REPLACEMENT, CAR IS STILL NOT SHIFTING PROPERLY, AND IS GETTING WORSE. DEALERSHIP ADVISED US THAT WE NEED AN ECM REPLACEMENT, AT A COST OF $1300. AFTER THE FACT, WE FOUND TOYOTA TSB TC002-06, WHICH DESCRIBES THE EXACT ISSUES OUR RAV4 IS HAVING. TOYOTA ADMITS IN THE TSB THAT THE ECM OF THE '01 THROUGH '03 RAV4'S CAN CAUSE THE HARSH SHIFTING THAT WE ARE SEEING, AND THAT TOYOTA MADE CHANGES TO THE "MANUFACTURING PROCESS TO REDUCE THE POSSIBILITY OF THIS CONDITION OCCURRING". THE RECOMMENDATION IS THE REPLACEMENT OF THE ECM. IT CANNOT BE REPROGRAMMED TO ELIMINATE THIS PROBLEM. THE RESULT OF THIS ECM FAILURE IS THAT THE CAR IS NO LONGER DRIVABLE, AS THE TRANSMISSION DOES NOT SHIFT PROPERLY AT ALL, AND IT CONSTANTLY LOOSES TENSION ON ITS CLUTCH PACK, RESULTING IN LOSS OF POWER TO THE ROAD. THE CONDITION GETS WORSE OVER A SHORT TIME. IN ONLY TWO WEEKS, THE CAR WILL NOT STAY IN ANY SINGLE GEAR WHEN DRIVING. A SEARCH OF THIS ISSUE ON THE INTERNET FOUND MANY OTHER PEOPLE HAVING THE SAME PROBLEM. OFTEN, THE ECM FAILURE CAUSES PHYSICAL TRANSMISSION FAILURE. THE DEALERSHIP WILL NOT STAND BEHIND THEIR FAULTY DIAGNOSIS, NOR WILL THEY MAKE TOYOTA HONOR THE WARRANTY, WHICH IS 80,000 MILES OR 8 YEARS. WE ARE UNDER THE YEARS, BUT OVER BY 8,000 MILES. HOW CAN THIS NOT BE TREATED AS A SAFETY ISSUE? IS IT NOT SERIOUS ENOUGH WHEN YOUR CAR SLIPS OUT OF GEAR IN TRAFFIC UNEXPECTEDLY? *TR