Spoke to Toyota and as I expected, unless I can reproduce the problem on demand, it is a waste of time bringing the car in
However, I am coming to some conclusions about this issue and believe the problem could be caused by overheating ATF (auto trans fluid). Problem arises in the following conditions:
- coming off motorway after running in overdrive (makes trans nice and hot because there is a fair amount of slip in O/D) and get stuck in stop/start traffic (stop/start very hard on ATF, made worse being on a hill and because there is no airflow through radiator which contains ATF cooler)
- I ALWAYS run the aircon which is a dealer-fitted unit not a factory-fitted unit (this worried me when I bought car 5 weeks ago). I am thinking they fit big ones to Australian cars because the heat exchanger sitting in front of the radiator is MASSIVE and is as big as the radiator itself (4 times the size of the one on my old commodore ). According to various cooling sites I visited, the radiator/ATF cooler effciency could be reduced to as little as 75% when the aircon is running
- my symtoms (delayed engagement followed by harsh engagement if the above conditions are met) could be explained by torque converter problems caused by overheating ATF in a transmission that shifts beautifully at all other times (ie. assuming no mechanical problem). Torque converter shudder (I get this in overdrive too) is also a characteristic symptom. Ford trucks have quite a few TSBs on this issue and FORD will fit a free auxiliary ATF cooler for trucks experiencing shudder in overdrive
- the A245E trans has a small ATF reservoir (2.9L) and is quite hard on ATF from what I have read. Other cars that have Aisin-Warner auto transmissions are the same. Also, the OEM ATF cooler in the radiator does very little from what I have read (at most 10% ATF cooling compared to after market coolers which can do as much as 60%)
So, I will have to experiment. It is getting cooler now as winter approaches and I will not use the aircon for a while and will do an ATF change. I will see if the problem reoccurs. If it doesn't, I will assume I have found the reason and will get my trans guy to fit an auxiliary trans cooler (very cheap). In fact, additional trans coolers are so cheap and can protect the ATF so well, you might as well do it anyway.
Of course, I could be wrong as I have a hard time explaining why this would happen in a new Corolla with a reputation for reliability and in a transmission that Toyota say can run forever on the factory fill of T-IV ATF (I could write another thread on this issue alone ....). Toyota don't even sell an auxiliary ATF cooler with their 950KG tow pack for the Corolla. I doubt I would be the only one with this problem however, from what I am told, I could easily be the only one sensitive enough to be worried by it