Toyota’s “absolute minimum” approach to Avalon transmission issues

Toyota owners across the country and around the world waited for what seemed like an eternity for a fix to the problems plaguing the dreaded five-speed-automatic transmission in Avalons and Camrys. After denying any problems existed, in June Toyota finally released a TSB to address low-speed hesitation in Avalons.

As one of the hundreds of thousands affected, and one who had Bill Kwong, press and media relations manager for Toyota N.A., tell me as late as January, 2007 that they had no data to support any problems with Avalon transmissions, I didn’t know what to expect when I took my 2006 Avalon Limited in for the TSB.

After having the TSB EG029-07 (ECM CALIBRATION: ENHANCEMENT
TO SHIFTING PERFORMANCE & SMOOTHNES) performed, I was able to put on some miles to gauge the effectiveness of the TSB fix.

First the good news: the hesitation seems to be largely fixed. So if you haven’t had it done yet, as Larry the Cable Guy would say “Get ‘R Dun”.

Now the bad news: the shifts are still as weak and sloppy as my knee the day after having arthroscopic surgery. The tranny still hunts to find the right gear, but at least it never is totally disengaged.

Furthermore, the extremely hard downshift and torque-converter-induced engine braking that occurs while coasting down to 33 mph before the TSB is still there… The TSB just moved down to a shift point of 28 mph.

It seems that Toyota took a page from my elementary school academic playbook: it did the absolute minimum to address the problem.

So if you are a Camry or Avalon owner and you are dissatisfied with the problem, the next step is to call 1-800-331-4331, which is Toyota’s national Consumer Hotline. It takes just few minutes. They will create a trouble ticket. This is the ONLY way that Toyota engineers will get the message if you are experiencing trouble, since dealers and district managers are not forwarding complaints to any central trouble reporting center.

A Four Wheel Drift reader passed along that when she called, the representative she spoke with actually explained she experienced similar problems on her Toyota! The representative also mentioned that too many people complain on chat boards and to dealers, but never call the 1-800-331-4331 number.

If we all call 1-800-331-4331, Toyota will get the message that just doing the absolute minimum to make the Avalon “not dangerous” is simply not enough.

Toyota addresses its transmission problem — sort of.

If the announcement were any quieter, the whole world would have missed it.  Hell, call it covert, because even guys like me who have been a thorn in Toyota’s side missed this one.

The big news is that Toyota FINALLY has a much anticipated “reflash” for its transmission control, which is intended to reduce the problems found in five-speed automatic-equipped Avalons.  If you recall, the Avalon trannies had a horrible issue of not selecting a gear from stops or low speed, which often resulted in near-catastrophe collisions.  Transmission shifting / downshifting was always rough.  This seemed to affect mostly 2005, 2006 and some 2007 Avalons, but also Camrys with the same V6/ five-speed-auto combo.

One would think that this being a safety issue, the Feds would have required a full-on recall.  Nope…Somehow Toyota managed to get away with just a TSB.  This means you will only get the fix if you go in, schedule an appointment and ask for the fix.  Even my local dealership — which told me they’d call me the second there was an available fix, didn’t make any attempt to contact me. 

Oh yeah — the fix is nearly two months old.

So far most people have been satisfied, but I’ll reserve comment on the success until well after I get my personal Avalon in sometime next week.

For reference — here’s the entire copy of the Technical Service Bulletin:

ENGINE

Technical Service
BULLETIN

June 6, 2007

Title:

ECM CALIBRATION: ENHANCEMENT
TO SHIFTING PERFORMANCE.
& SMOOTHNES.

Models:

’06 – ’07 Avalon

EG029-07
Introduction
To enhance shifting performance and smoothness during acceleration, the Engine
Control Module/ECM (SAE term: Powertrain Control Module/PCM) calibration has
been revised. Please use the following procedure to address customer concerns.

NOTE:

Before proceeding, verify the ECM (PCM) calibration has NOT been updated by
checking for the Authorized Modifications Label (shown in step 1 of the
Repair Procedure).

Applicable .
2006 – 2007 model year Avalon vehicles produced BEFORE the Production Change
Vehicles

Effective VIN shown below.

Production
Change
Information

MODEL PRODUCTION CHANGE EFFECTIVE VIN
Avalon 4T1BK36B#7U243331

Parts
Information

MODEL
YEAR
PREVIOUS PART NUMBER CURRENT PART NUMBER PART NAME QTY
20062006
89661–07450
89661–07471* ECM (PCM)( ) –89661–07451
2007 89661–07470
– N/A 00451–00001–LBL Authorized
Modifications Label
1

* The ECM (PCM) should NOT be replaced as part of the Repair Procedure.
NOTE:

Authorized Modification Labels may be ordered in packages of 25 from the Materials
Distribution Center (MDC) through Dealer Daily Dealer Support Materials System or by
calling the MDC at 1–800–622–2033.

Warranty
Information

OP CODE DESCRIPTION TIME OFP T1 T2
EG7023 Recalibrate ECM (PCM) 0.9 89661–##### 26 99

Applicable Warranty*:
This repair is covered under the Toyota Federal Emission Warranty. This warranty is
in effect for 96 months or 80,000 miles, whichever occurs first, from the vehicle’s
in-service date.
* Warranty application is limited to correction of a problem based upon a customer’s

specific complaint.
Toyota Supports ASE Certification
Page 1 of 4

ECM CALIBRATION: ENHANCEMENT TO SHIFTING PERFORMANCE & SMOOTHNESS – EG029-07 June 6,

2007

Required
Tools &
Material

REQUIRED EQUIPMENT SUPPLIER PART NUMBER QTY
TIS Techstream*
NOTE: Software version 2.00.008 or
later is required.
ADE TSUNT 1
GR8 Battery Diagnostic Station* SPX/OTC 00002–MCGR8 1

* Essential SSTs.
NOTE:

.
Additional Techstream units may be ordered by calling Approved Dealer
Equipment (ADE) at 1–800–368–6787.
.
The Toyota Diagnostic Tester and CAN Interface Module may also be used to
perform the service procedures listed in this bulletin.
.
The GR8 Battery Diagnostic Station (P/N 00002–MCGR supersedes the
Automatic Trickle Charger (P/N 00002–YA122–01) and Fast Battery Chargers
(Associated P/N ASE6003 and Christie P/N CAPPDQ). P/N 00002–YA122–01,
ASE6003, and CAPPDQ are now obsolete.
Calibration
Identification
Chart

MODEL MODEL YEAR
PREVIOUS
CALIBRATION ID
NEW
CALIBRATION ID
VDS
AvalonAvalon
2006 30705000
30705100 3070710030707100 BK36BBK36B
2007 30707000

NOTE:

Vehicles which have been flash reprogrammed using the procedures in this TSB
will contain upgraded 2007 model year OBD II logic. Refer to the 2007 model year
Avalon Repair Manual on the Technical Information System (TIS) when checking
Powertrain Diagnostic Trouble Codes (DTCs) on 2006 model year vehicles that
have been reprogrammed.

Page 2 of 4

ECM CALIBRATION: ENHANCEMENT TO SHIFTING PERFORMANCE & SMOOTHNESS – EG029-07 June 6,

2007

Repair 1. Check for the Authorized Modifications Label affixed to the vehicle in the

location
Procedure

shown in Figure 1. Confirm if the ECM (PCM) calibration has been updated. If the
calibration ID listed is NOT the latest ECM (PCM) calibration — go to step 2.

Replacement
ECM (PCM)
Part
Number

Calibration
ID(s)

THE FOLLOWING MODIFICATIONS HAVE BEEN MADE:
89661–07471
30707100
THESE MODIFICATIONS HAVE BEEN APPROVED
AS APPROPRIATE BY EPA AND CARB
DEALER CODE: DATE:
CHANGE AUTHORITY: TSB EG029–07

Date
Completed

Dealer Code
TSB Number

Figure 1. Location of Authorized Modifications Label on 2007 Avalon

2. Flash Reprogram the ECM (PCM).
NOTE:

.
The GR8 Battery Diagnostic Station MUST be used in Power Supply Mode to
maintain battery voltage at 13.5 volts while flash reprogramming the vehicle.
.
For details on how to use the GR8 Battery Diagnostic Station, refer to the GR8
Instruction Manual located on TIS, Diagnostics – Battery.
Follow the procedures outlined in TSB No. SS002–07, “Techstream ECU Flash
Reprogramming Procedure,” and flash the ECM (PCM) with the NEW calibration
file update.

3.
Start the engine and warm it up to normal operating temperature before test–driving.
4.
Test–drive the vehicle to confirm proper vehicle operation (and proper laser cruise
control operation, if so equipped).
Page 3 of 4

ECM CALIBRATION: ENHANCEMENT TO SHIFTING PERFORMANCE & SMOOTHNESS – EG029-07 June 6,

2007

Repair 5. Install the Authorized Modifications Label.

A. Using a permanent marker, enter the following information on the label:
Procedure
(Continued)

.
ECM part number: [Refer to the Parts Information section for the CURRENT
PART NUMBER]
.
Calibration ID(s): [Refer to the Calibration Identification Chart for the NEW
CALIBRATION ID]
.
Dealer Code
.
Repair Date
.
Change Authority (this TSB number): EG029–07
B.
Affix the Authorized Modifications Label to the vehicle at the location shown in
Figure 1. The Authorized Modifications Label is available through the MDC,
P/N 00451–00001–LBL.
Page 4 of 4

Two Key North American Executives “Retire” From Toyota

Toyota announced that two of its executives have retired. With Toyota getting spanked in the recent JD Power IQS ratings by FoMoCo and Porsche, as well as nagging problems with the Camry and Avalon (documented in great depth in our earlier report here on The Four Wheel Drift), we wonder whether these retirements were actually more of a “don’t let the door hit you in the ass while we’re kicking you out” type of move.

Here is the official word from Toyota. We’ll let you decide!

Convis, Smallenberg to Retire From Toyota
Sturdevant named new president of Canadian Autoparts Toyota, Inc.

06/13/2007 Erlanger, KY…Toyota announced today that Gary Convis, chairman of Toyota Motor Manufacturing, Kentucky, Inc. (TMMK), executive vice president of Toyota Motor Engineering & Manufacturing North America, Inc. (TEMA) and Gary Smallenberg, president of Canadian Autoparts Toyota, Inc., (CAPTIN) will both retire from the company.

“We thank both gentlemen for their focus of quality, vision and hard work during a very challenging period for Toyota in North America,” said Seiichi Sudo, president and COO of TEMA. “They have each had a tremendous impact on our growth. Both are true ambassadors for the Toyota Way and will be missed by all.”

Convis, 64, began his career with Toyota at New United Motor Manufacturing, Inc. (NUMMI), a joint venture with General Motors in April 1984 as plant general manager responsible for manufacturing operations and personnel. In May 2000, he joined TMMK, Toyota’s largest plant outside Japan as executive vice president and became president and eventually was named chairman. In June 2003, his responsibilities were expanded to include two additional assignments; managing officer at Toyota Motor Corporation and executive vice president of Toyota’s North American manufacturing operations. In his retirement, Convis will serve as senior executive advisor to Toyota.

Under Convis’ leadership, TMMK began producing the Camry hybrid in October 2006, the first Toyota hybrid vehicle built in North America and was responsible for bringing the North American Production Support Center to Georgetown, Kentucky, which trains Toyota’s 30,000 team members across the continent in a standardized manner.

Smallenberg, 60, began his career with CAPTIN in 1991 as vice president, secretary and member of the board. CAPTIN, located in Delta, British Columbia, Canada, is a wholly owned subsidiary of Toyota. In January 1998, he was appointed to president and corporate secretary and was also named as a member of the Board of Directors of Toyota Motor Manufacturing Canada Inc., based in Cambridge, Ontario.

Under Smallenberg’s leadership, CAPTIN has had a number of expansions, including a just-completed C$39 million/US$35 million expansion earlier this month – CAPTIN’s sixth in its 24-year history.

Deryl Sturdevant, 51, vice president, will become the new president of CAPTIN effective immediately. Before joining CAPTIN one year ago, Sturdevant served in a variety of roles at NUMMI, including general manager of plant operations, and assistant general manager of human resources, environmental, engineering, maintenance and new model introduction. Sturdevant joined NUMMI in February 1990.

Andrew McFadyen, 45, general manager, has been promoted to vice president of manufacturing and engineering of CAPTIN.

TMMK, located in Georgetown, employs about 7,000 team members and is Toyota’s largest manufacturing plant in North America. Its annual capacity is 500,000 vehicles and engines and produces the Camry, Camry hybrid, Avalon and Solara vehicles as well as four cylinder and V6 engines. TMMK has a total investment of nearly $5.5 billion.

CAPTIN employs about 300 team members and manufactures over 42 different designs of aluminum wheels for Toyota cars and light trucks. The company supplies Toyota assembly and service organizations in Japan, the United States, and Canada. CAPTIN’s total capacity exceeds 1.7 million aluminum wheels annually. CAPTIN has a total investment is C$247million/US$223 million.

Toyota Avalon Transmission Problems Expose Toyota’s Problem Reporting Problems

Editor’s Note: Updates to this story are available in the Toyota Transmissions Category

There is sad news to report to the thousands of owners of 2005, 2006 and 2007 Toyota Avalon models experiencing the dreaded five speed automatic transmission hesitation, bucking and binding problem: despite what your dealer has told you, Toyota is not working on any fix or reflash. I just got off the phone with Bill Kwong, media representative at Toyota, and he has confirmed that “the engineers do not see evidence that people are having problems.”

I personally own a 2006 Toyota Avalon Limited. It has been a wonderful car with the exception of the transmission, which hunts, searches, hesitates, and shifts hard. The problems (also blamed on the software controlling the torque converter) have caused me to encounter dozens of near collisions while entering traffic. Like most people, I went to the dealer service manager who told me “we get multiple questions per week on this…they’re working on a fix.”

No they’re not.

Since every dealer thinks a fix is in motion, few are even trying to report it the district managers. More disturbing is that there are plenty of documented cases where the district service managers are refusing to intervene, because they’ve pre-determined the transmission issues are “normal operation” — meaning the district managers are going out of their way to prevent the data from getting to Toyota engineers! Since none of the district managers are reporting it to Toyota, nothing is being done. The fact that Googling the issue brings up lemon law suits and discussions about it mean nothing to Toyota, because they don’t take third-party data into consideration.

Even Consumer Reports and Autoweek have reported on the widespread tranny issues. Bill gave me the same line he used in an article in Pittsburgh’s newspaper: “We’re up in the JD Power quality ratings.” Sure, Avalon has fewer reported problems versus the competition, and the rest of the car is pretty good, but that doesn’t solve the one very large, dangerous, annoying issue that is causing owners, dealers and journalists to scream “what the hell is going on?”

So what to do? If you have the issue, you must call 1-800-331-4331, which is Toyota’s national Consumer Hotline. This creates a national problem ticket that gains entry into their system. If you go directly to a dealer rather than call the hotline, you must demand the issue be brought to the attention of the district manager and sent to the national office.

We’d also like to hear about your experiences with this issue. Tell us about your car, where you’re located, the dealer (and what the dealer or district service manager) has told you.

When I asked Bill how many complaints it would take for Toyota to acknowledge the problem (percentage of the 100,000 per year made,) he didn’t have an answer.

It didn’t matter that I mentioned I have evidence dealers are even telling customers not to buy V6 Camrys until the issue is solved. Nor has it mattered that dealers have faced numerous lemon law suits.

Would you like to know why none of this matters to Toyota? Fixing the transmission software will result in lower reported fuel economy, which is something Toyota simply does not want to do. Toyota has made its surge on producing the most fuel efficient cars in class…and a software reflash would most likely reduce EPA mileage estimate on the Avalon, Camry and ES350 by 4mpg.

I’m pretty sure I didn’t sleep through that day in Advanced Marketing Strategy class at Boston University School of Management when we discussed which was worse — lower mpg or mass owner complaints due to a severe safety issue with the product….I believe the answer was: “screw the mileage rating, and protect your customers — make them happy, so they’ll live to buy another $35,000 product from you again in the near future.”

It’s great to see that GM and Ford aren’t alone…getting big means ignoring customers, even if you don’t mean to do it! Like Ford and GM, Toyota will probably wind up with a high-profile recall after too many people die — in this case when the transmission hesitates as drivers try to enter traffic or make left-hand turns.

Editor’s Note: Please see other Four Wheel Drift posts in the “Toyota Transmissions” Category for updated information regarding this issue.