In October 2005, Flavell returned to New Zealand after a season with Japanese club Toyota Verblitz.
In his last game for Toyota Verblitz in the 43rd Japan Championships on 12 February 2006 he was part of a team which lost to the top student side, Waseda University.
Flavell regained his All Black place in 2006 with two tests against Ireland before being injured for the rest of the season.
However he was left out of the All Black 2007 Rugby World Cup squad, being replaced by Sione Lauaki.
In May 2008, Flavell signed to play with the Japanese club Mitsubishi Sagamihara DynaBoars on a two-year contract, starting from the conclusion of the 2008 Super 14 season.