Bad Axle Gen4

My 2009 had no issues with axels in 225,000+ miles. I did do a front wheel bearing at 110k and the second at 187,000. Come to think of it.....those were the only 2 repairs I had with the car- Period

 

Search PRIUSCHAT - I recall maybe ½ dozen reported.

 

As @alanclarkeau kindly mentioned, there have been several reports; Toyota issued (and then withdrew) a service bulletin about it. See this previous thread: Clicking Sound on Regen Braking | PriusChat

 

I had my 2016 prius axle replaced twice, one at 35k and one at 60k. I believe most people don't hear it if it does occur and someone with three other prior priuis's said his all did it, but caused no issues in previous models. This is my first Prius and I noticed it. So far cross my fingers the noise has not yet returned the third time but this issue is only covered to 60k under factory warranty.

 

SW Florida? I know the Bradenton/Sarasota rather well, I don't recall road surface issues (potholes, expansion cracks) Any idea why your car would have 2 failed FE axles? One on each side, or on the same side?
OEM 15"s?

I've just scanned the 13 page "Clicking sound on regen braking" thread. Any idea if Toyota changed CV joint vendors, or perhaps they changed the quantity/quality of the CV joint lube?

Thanks!

 

What is not normal is when you say clicking noise happens. CV joints in my experience and commonly known to click during turns not breaking. Could be mechanics takeing advantage of warranty. NOT the first time I've seen this. I knew some dealer mechanics that would replace a fuse and tell manufacturer it was shorted wire and dash had to come apart.

Posted via the PriusChat mobile app.

 

I don't have this problem, but I'm a proactive (neurotic/OCD) car owner who likes to learn/know about possible weaknesses.

I agree with you that normally CV failure/clicking is noticed while turning. In the extensive thread about this, someone(s) mentioned the possibility that the regen braking causes a different kind of torque to the shaft. It sounds sketchy to me, but maybe it's possible?

I'd like to know what part of the axle assembly is making the sound? Is it actually the CV joint?

 

The CV joint itself. There is caged ball-bearing fixed to the shaft then slid into sized channels on end piece. The channels and bearings ware and then start clicking.

Posted via the PriusChat mobile app.

 

I drive pretty easy in the SW florida area (no real potholes issue here). Normally back and fourth on US41 for roughly 30 miles each way for my commute. I wouldn't say its a failure but more of a noise that wasn't there before and I am proactive and notice odd noises ahead of time. Most of the mechanics wouldn't even hear it till I recorded the noise on my phone and cranked it up in the car (took several visits both times to get them to do the repair). I can say it makes more of a whirling sound now than when it makes the clicking noise. Now that I am out of warranty I can say I am not going to pay the $800 to get it fixed anymore unless there is a real failure of the axle itself. FYI the clicking noise does NOT occur when shifting into neutral and using friction brakes.

 

Continued clarification is appreciated. Still speculating if Toyota changed vendors, if they modified the design (not likely, except maybe specified harder steel from the vendor?), or have installed a thicker lube, which would dampen what seems for some to be a naturally occurring clicking? Curious minds want to know...
If this is simply an axle/CV replacement, an indie shop should be able to do the repair for about 1/3 what your dealership is charging...IMHO, of course. (I haven't examined the drivetrain, is it more complicated than a traditional FE axle/CV?)

 

Had my driver side axle replaced at 34k. Took the dealer 5 tries to find the bad axle. No problems since.

Posted via the PriusChat mobile app.

 

I'm sure there's more to that story, but doesn't sound good, considering there's only 4 wheels on the car, lol.

 

Reminds me of the look on my wife's face when she came out in the garage and her Rav4 was up in the air with all four wheels spinning while I was trying to find the bad wheel bearing with a stethoscope.

 

Which reminds me of The Exorcist, lol.