6.7% of complaints about the 2004 Toyota Prius came in the first year, which is unremarkable for a 2004 vehicle — around the middle of the 236 model-years on record. The median complaint arrives at 5.4 yr in service. The most-reported system is electrical system (178 complaints), typically at 2.9 yr or about 29,000 miles.
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.
Over time, the splines may wear and eventually fail resulting in a loss of steering ability, increasing the risk of a vehicle crash.
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.
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.
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.
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.
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.
THIS COULD RESULT IN A LOSS OF STEERING CONTROL OF THE VEHICLE.
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.
THIS MAY INCREASE THE RISK OF INJURY TO THE OCCUPANT IN THE INVOLVED SEATING POSITION IN THE EVENT OF A CRASH.
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.
IF THE SWITCH IS INOPERABLE, THE BRAKE LIGHTS WILL NOT ILLUMINATE AND CAN INCREASE THE RISK OF A CRASH.
REPORTED TO TOYOTA ON 2/7/04 FILE #200402110133. WHILE DRIVING ON THE HIGHWAY, 70MPH, CRUISE CONTROL ON, BOTH MY WIFE AND MYSELF HAVE ACCIDENTALLY BUMPED THE GEAR SHIFT KNOB WITH OUR HAND AND PUT THE PRIUS INTO DYNAMIC BRAKING MODE (DBM). THE SEMI-TRUCK BEHIND ME ALMOST RAN ME OVER BEFORE I COULD GET THE CAR BACK INTO DRIVE. VERY DANGEROUS!!! THE BRAKE LIGHT DOES NOT COME ON DURING DBM. TOYOTA SHOULD CHANGE THE SOFTWARE TO MAKE A DELAY IN THE GEAR-SHIFT FOR DBM SIMILAR TO SHIFTING INTO NEUTRAL?*AK
FLUID ON LEFT REAR TIRE RIM AND LOSS OF HUB CAP. DISCOVERED LEAKING BRAKE CYLINDER ASSEMBLY AND SOAKED DISK BRAKE PADS. MASTER CYLINDER BRAKE LEVEL DOWN TO TO MINIMUM FILL LEVEL. BRAKE FLUID POOLING ON GARAGE FLOOR UNDER LEFT REAR WHEEL. *AK
DT: THE CONTACT STATED THE ABS FAILED. THE ABS AND VSC LIGHTS FLICKERED WHILE SLAMMING ON THE BRAKES AND ALL FOUR TIRES LOCKED. THE LIGHTS CAME ON LAST WEEK WHEN THE FUEL WAS LOW IN THE VEHICLE. THE ABS WAS STILL NOT WORKING. HE WAS TAKING THE VEHICLE TO THE DEALERSHIP TODAY. *AK UPDATED 1/25/2006 - *NM
WHILE DRIVING VEHICLE STALLED. CONSUMER RESTARTED THE VEHICLE, AND PULLED OVER. CONSUMER NOTICED ALL WARNING LIGHT APPEARED ON THE DASHBOARD AND REMAINED ON. CONSUMER HAD THE VEHICLE TOWED TO THE DEALER FOR INSPECTION, AND MECHANIC COULD NOT DUPLICATE THE PROBLEM, BUT INSISTED THAT WARNING LIGHT SHOULD BE TURNED OFF. *AK