Avensis NCT fail - cracked doors

forumuser

I took my 09 Avensis for its NCT last night and it failed because of cracking on the 2 front doors. It was dark last night so the tester couldn't properly point the cracks out to me but pointed somewhere around the door hinge. I've had a quick look today but nothings jumping out at me but honestly I wouldn't know what I'm looking at anyway. He mentioned that it's a common enough fault and he thinks Toyota were fixing under recall at some stage.
Does anyone have any experience of this? Should I contact the local main dealer first (car not bought there) or is there a different route I need to take?
I'll be taking it to my mechanic in a few days but thought it was worth asking here too. Thanks.

PauloMN

forumuser wrote: »

I took my 09 Avensis for its NCT last night and it failed because of cracking on the 2 front doors. It was dark last night so the tester couldn't properly point the cracks out to me but pointed somewhere around the door hinge. I've had a quick look today but nothings jumping out at me but honestly I wouldn't know what I'm looking at anyway. He mentioned that it's a common enough fault and he thinks Toyota were fixing under recall at some stage.
Does anyone have any experience of this? Should I contact the local main dealer first (car not bought there) or is there a different route I need to take?
I'll be taking it to my mechanic in a few days but thought it was worth asking here too. Thanks.

Found this thread from a few years ago on the subject.

Ring your nearest main Toyota dealer and ask if you should have been notified of a recall. Maybe a previous owner was but didn't get it done? Anyway they should be able to put you right.

bazz26

It's more than likely the check straps on the door hinges, it's a well known issue with that model. Toyota were replacing/fixing these some time back. Not sure how you will get on with them regarding an 11 year old car but worth a shot.

There is some hope though as in this thread they were replaced by Toyota on a then 7 year old Avensis:
https://www.boards.ie/vbulletin/showthread.php?t=2057659314

colm_mcm

What part of the NCT can they fail you on for this particular issue?

forumuser

colm_mcm wrote: »

What part of the NCT can they fail you on for this particular issue?

On the report it's listed as 'Bodywork (35) - Secondary structure condition - cracked/fractured'

Thanks - I saw that thread but it was scant on detail. I'll contact main dealer and see what they say.

Badabing

My 2011 Avensis was failed for the same thing last July, i went to Toyota Main dealer and they replaced the two doors within 3 weeks no problem.

TigerTim

My 2012 Avensis had the 2 front doors replaced by the Toyota dealer about 3 years ago when I bought it from them. Common flaw apparently.

T.

mickdw

TigerTim wrote: »

My 2012 Avensis had the 2 front doors replaced by the Toyota dealer about 3 years ago when I bought it from them. Common flaw apparently.

T.

Replacing doors - pretty annoying assuming the entire door is replaced so painting etc required.
Not nice having paint work for an issue like this if a car was relately new.

tcawley29

mickdw wrote: »

Replacing doors - pretty annoying assuming the entire door is replaced so painting etc required.
Not nice having paint work for an issue like this if a car was relately new.

But a very handy way to get rid of and dings and scratches from carpark morons

Leonard Hofstadter

Very common problem with these cars, we've had ours replaced FOC by Toyota twice.

elperello

OP were the doors giving you any trouble before the NCT?

Sounds a bit like "mission creep" to me.

BronsonTB

Thread on the owners group showing pic examples of this issue...


https://www.toyotaownersclub.com/forums/topic/171984-front-door-cracking-at-check-strap-reinforcing-and-repair/

sumo12

Not a recall but Toyota have been covering them, even UK imports. Not sure if there is now a cut off in relation to age of the vehicle. I would have expected most of them to be picked up at NCT by now. NCT testers are very aware of it and tend to check the area forensically...

elperello

I'm still not seeing how this is an NCT issue.

It's only the stop straps that could possibly be affected.

No fear of the door falling off.

colm_mcm

elperello wrote: »

I'm still not seeing how this is an NCT issue.

It's only the stop straps that could possibly be affected.

No fear of the door falling off.

That’s exactly what I’m thinking.

Eoinbmw

Any noise when opening door like pops or creaks?
They usually get noisy when they fail!

elperello

What we really need is the OP to come back and clarify what was the issue.

Were the hinges the problem or the stop straps?

What repair was done and did it pass?

zilog_jones

elperello wrote: »

I'm still not seeing how this is an NCT issue.

It's only the stop straps that could possibly be affected.

No fear of the door falling off.

It's a stress fracture right in-between where the door hinges are - there must be significant load there when the doors are opened. Considering how Toyota have been dealing with this I'd say it's a fairly serious structural issue.

In the case of an impact it could increase the chance of the doors coming off.

elperello

zilog_jones wrote: »

It's a stress fracture right in-between where the door hinges are - there must be significant load there when the doors are opened. Considering how Toyota have been dealing with this I'd say it's a fairly serious structural issue.

In the case of an impact it could increase the chance of the doors coming off.

In all the reports about this problem there has been no mention of a door coming off either in a collision or otherwise.

That's not to say it never happened but you would expect it to be reported if it did.

Toyota are not dealing with this as a serious structural issue. There was no recall and they are only fixing them if people come to them with the problem.

forumuser

Thanks for all the replies. So I took the car to the local main dealer who were very familiar with the issue. The cracks are on both doors just where the hinge is bolted to the door and are quite small, they said they've seen a lot worse and worst case scenario door can fall off. I'm sorry for no pictures but my phone camera is rubbish. There was no argument about the work being done by them although they did double check with head office because of the age of the car, it's booked into a bodyshop and work will take 3 days. As others have said it's not a recall issue but seems they will do it as 'goodwill' if it's brought to their attention.

Stallingrad

forumuser wrote: »

Thanks for all the replies. So I took the car to the local main dealer who were very familiar with the issue. The cracks are on both doors just where the hinge is bolted to the door and are quite small, they said they've seen a lot worse and worst case scenario door can fall off. I'm sorry for no pictures but my phone camera is rubbish. There was no argument about the work being done by them although they did double check with head office because of the age of the car, it's booked into a bodyshop and work will take 3 days. As others have said it's not a recall issue but seems they will do it as 'goodwill' if it's brought to their attention.

Well done Toyota. I'm assuming 2 new doors. You might want to ensure they blend the doors when painting into the adjacent panels, otherwise the colour match will never be right.

CJhaughey

Stallingrad wrote: »

Well done Toyota. I'm assuming 2 new doors. You might want to ensure they blend the doors when painting into the adjacent panels, otherwise the colour match will never be right.

I think Toyota's aftercare is the best in Ireland of all the major makes.
Very few other makes would even give you the time of day with a 2 year old car yet they are replacing the doors.

forumuser

Stallingrad wrote: »

Well done Toyota. I'm assuming 2 new doors. You might want to ensure they blend the doors when painting into the adjacent panels, otherwise the colour match will never be right.

Yes, they're replacing both doors as both are listed on the NCT fail sheet. And said they'll blend the colour, I don't want the new doors making the rest of the car look bad!

elperello

forumuser wrote: »

Yes, they're replacing both doors as both are listed on the NCT fail sheet. And said they'll blend the colour, I don't want the new doors making the rest of the car look bad!

Thanks for reporting back.
That's a great result for you and you are not even a customer of the garage.
How many owners before you?

elperello

This ad is for another 2009 Avensis.


https://www.donedeal.ie/cars-for-sale/2009-toyota-avensis-automatic/27141452



It says just had two new doors at main dealer after NCT failure and the cost of the work was €2k.

colm_mcm

Guarantee they didn’t pay for the work. Interesting that it’s a uk import.

MAYOMICK

colm_mcm wrote: »

Guarantee they didn’t pay for the work. Interesting that it’s a uk import.

Mine failed Nct in 2016 and the doors were replaced. It was an Uk import.However when I brought in back to Nct for reinspection the tester was surprised that it was done for free as it was an import.

elperello

colm_mcm wrote: »

Guarantee they didn’t pay for the work. Interesting that it’s a uk import.

I'd say you are right.

If they had to it would be an economic write off.

Must be costing Toyota a fortune, they won't be fans of NCT.

show me the money.1

Failed NCT today for the same problem.
Can I ask which Toyota garage replaced the doors?

sumo12

show me the money.1 wrote: »

Failed NCT today for the same problem.
Can I ask which Toyota garage replaced the doors?

Visit your local dealer, I'm sure they will be able to help

Elmer Blooker

show me the money.1 wrote: »

Failed NCT today for the same problem.
Can I ask which Toyota garage replaced the doors?

Me too, failed with the same problem.
I've decided to PM you and tell what you have to do.

Stallingrad

Stallingrad wrote: »

Well done Toyota. I'm assuming 2 new doors. You might want to ensure they blend the doors when painting into the adjacent panels, otherwise the colour match will never be right.

Standard practise for any half decent body shop. Toyota dealer wouldn't be using a poor one to be fair.

CJhaughey

LIGHTNING wrote: »

Cough Cough

https://www.boards.ie/vbulletin/showthread.php?t=2057987914&page=9

That may just be an isolated incident or the actual head unit can't be upgraded in those models though.
I mean look down through the years, Repainting Red Avensii, Landcruiser 90 rear axle replacements, Avensis doors...
They have a decent reputation in all fairness.

keyboard_cat

I have a 2010 Avensis with cracked doors it has not failed an NCT (due again in 3 months)
but the wind noise from the doors is really bad, has anyone who got their doors replaced noticed a reduction in wind noise?

show me the money.1

Elmer Blooker wrote: »

Me too, failed with the same problem.
I've decided to PM you and tell what you have to do.

Cheers I went to my local dealer they took photo's and said they would come back within 2 weeks also said if I wanted to pay for it to be done it would cost €2800 + VAT, I laughed at him.

BronsonTB

keyboard_cat wrote: »

I have a 2010 Avensis with cracked doors it has not failed an NCT (due again in 3 months)
but the wind noise from the doors is really bad, has anyone who got their doors replaced noticed a reduction in wind noise?

As it's a visual check, not always picked up on or in bad enough condition to fail. (Testers opinion's vary)
I too suffer the wind noise.


Fingers crossed for your next test

show me the money.1

Toyota called back yesterday evening and confirmed the will cover the doors under warranty.

keyboard_cat

FYI for anyone thinking of getting it done. Toyota did both doors on my 2010 Avensis for free, they had the car for 5 days and I was able to purchase new window seals for both doors ~230 euro and have them put in at the same time. Wind noise is reduced a good bit so worth while in my opinion.