2004 Toyota Prius problems

What is wrong

Toyota is recalling certain model year 2004-2009 Prius vehicles manufactured August 6, 2003, through March 30, 2009 and FCHV-adv vehicles manufactured December 12, 2008, through September 13, 2011. During manufacturing, a scratch may have occurred inside of the electrically driven water pump at the coil wire. The coil wire may corrode at the scratched portion.

Risk

The corroded coil wire may break and the water pump could stop. The corroded coil wire could cause a short circuit between coil wires and a possible open fuse, creating a stall-like condition of the hybrid system while the vehicle is being driven. This may increase the risk of a vehicle crash.

Remedy

Toyota will notify its owners, and dealers will replace the electric water pump, free of charge. The recall began on January 17, 2013. Owners may contact their Toyota dealer or the Toyota Customer Experience Center at 1‑800‑331‑4331.

Recall number 12V536000 · Recall details

What is wrong

Toyota is recalling certain model year 2004-2009 Prius vehicles manufactured August 5, 2003, through March 30, 2009. The affected vehicles have a steering intermediate extension shaft assembly built with metal splines that complete the connection from the steering wheel to the steering gear. These splines may have been manufactured with an insufficient hardness.

Risk

Over time, the splines may wear and eventually fail resulting in a loss of steering ability, increasing the risk of a vehicle crash.

Remedy

Toyota will notify owners, and dealers will inspect the extension shaft and replace it if it is one with insufficient hardness, free of charge. The recall began during December 2012. Owners may contact their Toyota dealer or the Toyota Customer Experience Center at 1‑800‑331‑4331.

Recall number 12V537000 · Recall details

What is wrong

Toyota is recalling certain model year 2004-2010 passenger vehicles. The accelerator pedal can get stuck in the wide open position due to its being trapped by an unsecured or incompatible driver's floor mat.

Risk

A stuck open accelerator pedal may result in very high vehicle speeds and make it difficult to stop the vehicle, which could cause a crash, serious injury or death.

Remedy

Toyota filed an amended defect report on november 25, 2009, stating that dealers will modify the accelerator pedal and, on certain vehicles, alter the shape of the floor surface under the pedal. These changes address the risk of pedal entrapment due to interference with the floor mat. Redesigned accelerator pedals will become available beginning in april 2010 and dealers will replace any modified pedal with the new pedal if desired. Also, dealers will replace any genuine toyota or lexus all-weather floor mats with redesigned all-weather mats, or repurchase the previous mats from owners who do not want the new ones. Additionally, software modifications will be installed on camry, avalon and lexus es 350, is 350 and is 250 models that will ensure that the brake overrides the accelerator in the event both brake and accelerator pedals are applied. Toyota will begin mailing letters to owners on december 31, 2009. Owners may contact toyota at 1‑800‑331‑4331, lexus at 1‑800‑255‑3987.

Recall number 09V388000 · Recall details

What is wrong

The intermediate shaft and sliding yoke in the electric power steering system can crack when large forces are applied and the connection may separate or the sleeve may fracture.

Risk

This could result in a loss of steering control of the vehicle.

Remedy

Toyota will replace the steering intermediate shaft and inspect the sliding yoke and replace it if necessary. The recall began on june 9, 2006. Owners may contact toyota at 1‑800‑331‑4331.

Recall number 06V188000 · Recall details

What is wrong

On certain vehicles, due to improper assembly of the air bag inflator, which is used in the side air bag, the curtain shield air bag, and the knee air bag assembly, some inflators were produced with an insufficient amount of the heating agents necessary for proper air bag deployment. In this condition, the expansion force of the gas may be insufficient to properly inflate the air bag when the SRS system is activated during a crash.

Risk

This may increase the risk of injury to the occupant in the involved seating position in the event of a crash.

Remedy

Dealers will replace the specific SRS air bag. The recall began on april 6, 2006. Owners may contact toyota at 1‑888‑270‑9371, scion at 1‑866‑548‑1851, or lexus at 1‑800‑255‑3987.

Recall number 06V096000 · Recall details

What is wrong

Certain passenger vehicles may be equipped with an improperly designed brake light switch. A silicon oxide build-up occurs on the contacts inside the brake light switch, which can make it inoperable.

Risk

If the switch is inoperable, the brake lights will not illuminate and can increase the risk of a crash.

Remedy

Dealers will replace the brake light switch. The recall began during december 2004. Owners should contact toyota at 1‑800‑331‑4331.

Recall number 04V558000 · Recall details

the federal safety agency received a petition on or about July 18, 2022, requesting that Federal Motor Vehicle Safety Standard (FMVSS) 141 be applied to all electric and hybrid vehicles operating in the United States. The petition can be reviewed at under ODI Number 11486072. FMVSS 141 establishes performance requirements for pedestrian alert sounds for motor vehicles. The standard applies to hybrid and electric vehicles that have a gross vehicle weight rating of 4,536 KG or less or are defined as low-speed vehicles. The standard became fully applicable to all such vehicles manufactured on or after March 1, 2021.On January 27, 2023, the federal safety agency opened Defect Petition (DP) 22-005 to evaluate the subject matter described in the petition. On June 24, 2023 and as supplemented on June 25, 2023, the petitioner notified the federal safety agency he was withdrawing his petition. The petitioner indicated that, based on his review of data, there is no justification for asserting potential benefits that could be derived from actions sought by my petition. Based on the petitioner's withdrawal, DP22-005 is closed. Closure of this DP does not represent a determination by the federal safety agency regarding the subject matter of the petition.

DP22005

The Office of Defects Investigation (ODI) received a January 2013 defect petition requesting that it open an investigation on Model Year (MY) 2004-2009 Toyota Prius vehicles to address a possible manufacturing safety defect related to the steering column intermediate shaft.During the defect petition evaluation, ODI: 1.Reviewed the petition and its enclosures; 2.Reviewed the subject steering system layout; 3.Examined the Petition Vehicle?s history, including its repair history; 4.Reviewed and followed-up potentially related consumer complaints; 5.Assessed Safety Recalls 06V‑188 and 12V‑537; and, 6.Requested and examined complaint, claim, field report, service history, and warranty information from Toyota.ODI's review revealed that the petition vehicle had been recalled (Recall 06V188) to remedy a defect in the system identified in the petition with the remedy taking place prior to the failure that prompted the petition. Circumstances point to incorrect reassembly of the petitioner's vehicle by those who performed the recall remedy.ODI examined the issues raised by this petition to identify any related safety defect trend in the general subject vehicle population.That review identified a low rate of related consumer complaints (twenty-five over a eight year period from a population of over 600,000 vehicles) and no pattern that would identify either a safety defect not already covered by the two existing steering safety recalls by Toyota or a systematic problem with either recall remedy.Based on this evaluation, ODI does not believe that additional investigation will lead to a finding that a defect related to motor vehicle safety exists in the subject vehicles. Therefore, in view of the need to allocate and prioritize the federal safety agency?s limited resources to best accomplish the agency's safety mission, the petition is denied. The denial of this petition does not constitute a finding by the federal safety agency that a safety-related defect does not exist. The agency reserves the right to take further action if warranted by the circumstances.For more information, see the Federal Register notice in the public file for this action select the federal safety agency ID, enter: DP13001)The ODI reports cited above can be reviewed on-line under the following the federal safety agency ID numbers:10407520, 10418710, 10429551, 10473654, 10478195, 10478053, 10437229, 10489425, 10510722, 10639984, 10648277, 10499778, 10712626, 10723196, 10787530, 10808124, 10838803, 11071646, 11098144, 11099507, 11102659, 11160767, 11192607, 11287550, 11287606

DP13001

Odi opened pe05-029 based on 33 reports of alleged gasoline engine stalling on the subject vehicles.the subject vehicles are gasoline/ electric hybrid vehicles that can be operated in gasoline or electric modes, or a combination of both depending on the power demand.all reports allege that the gasoline engine shut down suddenly without warning.some of the complainants reported that the vehicle continued to operate using the electric mode for a period of time after the gas engine stalled and some reported that the vehicle shut down at the same time that they felt the gas engine stalled.some consumers reported that they were able to restart the vehicle either immediately or after allowing the vehicle sit for a short time, whereas others reported that they had their vehicle towed.during pe05-029, additional failure data was identified as noted in the failure report summary above.the complaint data represents incidents where engine stalling was alleged or where the vehicle was alleged to have one of the various conditions that causes the gas engine to stall.in its august 26, 2005 response to odi's information request, toyota identified various conditions that could cause the subject vehicles to experience a gas engine stall.if this happens, the driver is alerted by an audible sound and various warning lights.the vehicle will continue to operate in the electric mode and the electrically-powered brake and steering operation will continue to function normally. Analysis of the warranty data indicated that over 97% of vehicles experiencing a gas engine stall resulted from an issue with the program logic in the electronic control module (ECM) system, which may cause the ECM system to not start the gas engine when required.as a result, the vehicle will enter the limited operation mode described above.the majority of the odi complaints also indicated that the driver experienced this condition in conjunction with the engine stall. During october 2005, toyota informed odi that it would initiate a special service campaign (ssc) to reprogram the ECM software on approximately 75,000 my 2004 and early 2005 subject vehicles to address the gas engine stalling condition.during this ssc, dealers will also apply special dielectric grease to a transaxle connector to prevent water intrusion which may also cause similar limited operation conditions.based on odi's analysis, this remedy should address most of the incidents resulting in a limited operation mode.given these circumstances, further use of the agency resources in this matter does not appear to be warranted.accordingly, this investigation is closed.the closing of this investigation does not constitute a finding by the federal safety agency that a safety-related defect does not exist.the agency will continue to monitor complaints and other information relating to the alleged defect in the subject vehicles and take further action in the future if warranted.

PE05029