Hi there

My Alphard Hybrid 2.4 2006 Camper conversion developed an intermittent gearbox issue on a recent run up to the lake district. After a few long days of driving and a few very steep hills the gearbox would crunch when changing down, usually at low speed in low gears. It did it for a couple of days and hasn't since apart from on one or two occasions.

This is a new thing as it hasn't missed a beat in the 10 months we've own it.

The box does seem a little noisier or maybe I'm just noticing engine noise more now?

The garage that has looked after the van for the last 6-7 years said they wont touch the gearbox.

Is this a common issue?

Has anyone got a recommendation for a specialist who could take a look in the London Essex area? I saw someone recommending Rainham Motors...has anyone used them?

Thanks

Edited July 7Jul 7 by Jerry_R
Vehicle details and spelling error!

Update

I've been advised to talk to Richard at CAMS in Potters Bar as they are the most local expert in this area. Anyone had any dealings with them? I spoke on the phone to Richard who seems to know what he's doing.

He asked me to find a Gearbox service kit which I should be able to find online. Unfortunately I have absolutely no idea where to start with this.

Does anyone have any trusted places to source this kind of thing? There seem to be various versions but can't find one that explicitly states that it is for a hybrid. Pardon my ignorance but does it matter if it is one for a 2.4 petrol alphard? Some seem to have a filter and some don't. I've attached the VIN plate to help identify the version if that helps.

The 10 series hybrid is quite a bit different from both a regular automatic gearbox, and from other Toyota hybrids - this describes the system:

https://toyota-club.net/files/faq/21-11-20_faq_hybrid_thsc_en.htm

So anything you do is going to be specific to that, or the 2001-2005 Estima hybrid which shares the same setup. (although I don't know if there are parts differences between the two)

I don't know if there's a gearbox service kit available or whether you have to buy individual parts. Amayama has the parts diagram but isn't showing a service kit:

https://www.amayama.com/en/genuine-catalogs/epc/toyota-japan/alphard/ath10w/42993/chassis/3901?frame_no=ATH10-0024738

Perhaps you could show him that diagram and ask what parts to get?

Edit: forgot to mention that the transmission is called the P210, under the THS-C (Toyota Hybrid System - CVT) banner. If I search on that I find somebody in Australia selling aftermarket service parts:

https://www.alltranz.com.au/shop/drivetrain/hybrid-transmission/P210/

I wouldn't buy those, but it's a useful clue as to which parts to get from Toyota. As the THS-C uses a CVT belt, that would probably be on my list, as is the gasket, probably the seals and it'll need the right CVT fluid which is Toyota's TC transmission fluid. The garage should be able to confirm.

If there is something actually damaged inside it, they don't show the breakdown of internal parts so it may not be possible to get them without taking them from a scrap unit or buying a new transmission (~$3000). But cross that bridge if you come to it.

Edited July 13Jul 13 by Ptarmigan
Clarify

Ah, I spotted a line in the Toyota Club page: "The front transaxle P210 is built using CVT K110 components". I suppose that refers to the CVT belt part of the transmission, rather than the planetary gear set and electric motors which are specific to the P210 (unlike other Toyota hybrid transmissions, there is only one electric motor generator, not two).

There are K110 rebuild kits and repair manuals. So it would probably be worth having those on hand, but it may well deviate from the K110 procedure.