Prius stalling

<div class='quotetop'>QUOTE(deborawkart @ Jul 18 2007, 05:42 PM) [snapback]481290[/snapback]</div>

WOW, that's an expensive decimal point (on the man-hours) to miss! Probably .3 hours. If you reported the problem 4 years ago Toyota should still cover it since it took them 4 years to diagnose!

 

Contact Robert Wilson here (bwilson) for rebuilt accelerator pedal position sensors. Installation is easy for any mechanic, no need to go to Toyota.

Wayne

 

Been there, done that. Results
Part cost=448.39
Labor=94.95

Part#: 78010-47031

The whole pedal is replaced and only the little dual potentiometer is bad. The gas pedal assembly looks super easy to replace (one connectors and two bolts). Would have done it myself if I was aware that this was the problem part.

Additional note. The problem I had was the 2001 Prius suddenly slowing down while driving on the interstate. Had enough power to limp to the dealer. Have heard this refered to as the "Big Hand" syndrome as it feels like a big hand grabbing and slowing down the car. I have had "close to stalling" effects also before the pedal replacement. The occasional failure of the gas pedal is a known issue with the early Prius's. The later Prius's have a completely different sensor as a result.

 

Hi Deborah, greetings from southern China! I did accelerator pedal rebuilds but as mentioned above, turned the 'business' over to Bob Wilson before I left for these parts. He ought to have at least one available and you can find him here at Prius Chat for private messaging.

You might actually do the rebuilding yourself. Join the yahoo toyota-prius-sat2 group and read my 'how-to' document there. Then see if you are up for it.

I have seen them offered on ebay as well, but not often. The salvage vehicle dismantlers ought to be able to figure out how to separate them from the cars. It is correct that they take about 5 minutes to remove, once you get yourself squished into the driver's footwell.

Xingyun!

 

Hi folks,

I sent a PM already and am waiting on a reply. The general approach is:

1) PM or e-mail a shipping address.
2) I'll send a tested pedal assembly back with instructions, a tool and return shipping.
3) Replace the accelerator, either yourself or your mechanic
4) Test it
5) Return the old accelerator with postage and something for my wife, Holly, so she'll let me continue

After I figure out all of the costs associated with this, we'll setup a PayPal system for the 'core' charge. Just bear with me as I get used to the system.

So I'm wondering, will Doug visit the new Toyota Prius plant in China someday? <grins>

Bob Wilson

 

abq sfr is not exaggerating. If you reported this problem to any dealer during the warranty period it's covered until it is fixed.

 

At least be thankful that they designed it so the failure mode is to have less acceleration!

 

I'll provide some answers till China (or Bob) awakes.

1) Willing to bet that rebult potentiometer is from the previous "Big Hand" victim.
2) No switchs on the pedal, just a dual potentiometer in one plastic case.
3) ??? (How would they know?)
4) The pedal I'm holding in my hand has one connector and two bolt holes
5) Ten minutes.
6) Let the experts fill in here. Unlikely to be very long.
7) Can't answer for them. Realize the folks helping you save $$$ are not in a good position to provide anything other than a real bargain based on good faith and their time. (Put yourself in their shoes.)

 

Bob, is that Prius plant near Beijing? That is a fur piece from Kunming. I understand that they have sold only a couple of thousand in China. Also understand that 'Sinopec' still sells fuels with quite high sulfur content, so this may not be the ideal home for fussy cars like Prius. I remember the late Dave Hermance' opinion that they'd sell only one in China ([attachmentid=9944]hope that wasn't meant to be a secret

Xingyun is 'luck' in my Chinese dictionary. So far people just laugh when I attempt to speak Chinese, so use at own risk.

I will attempt to attach the pdf file here. I am sure that Debora could have gotten it, by joining that group.

As far as the rebuilt pedals, I got them one by one. Did the fix, swapped it into my 2001 Prius, and drove with it until it was called for elsewhere. In other words, each one that passed through me was extensively road-tested.

The pdf does not mention my newest trick, which was using CAIG fader-lube on the potentiometers. Google Caig and see if you want to try their stuff. People who maintain big audio soundboards use that stuff so I guess it's pretty good. They hate crunchy potentiometers.

On the installation, there is no rebooting. If you start Prius with the pedal unplugged, you will get an error code (so don't do that). It really does take only 10 minutes, with a 10 mm socket wrench, once you squish yourself into the space available.

 

Hi Debra,

<div class='quotetop'>QUOTE(deborawkart @ Jul 19 2007, 02:36 PM) [snapback]481744[/snapback]</div>

These are from Doug's inventory and have a mixed origin. Doug would send one with cleaned contacts to swap with a failing unit. He'd clean the contacts of the returned unit and that would be the new inventory.

<div class='quotetop'>QUOTE(deborawkart @ Jul 19 2007, 02:36 PM) [snapback]481744[/snapback]</div>

Your mechanic is correct. In fact, if you want to do it yourself, I just attached Doug's procedure and it isn't that hard. Certainly, your mechanic should be able to handle it. The only difference is I probably would minimize any mechanical contact and use a contact cleaner bath and through drying before sealing the unit up again.

<div class='quotetop'>QUOTE(deborawkart @ Jul 19 2007, 02:36 PM) [snapback]481744[/snapback]</div>

A#6 - All the work is done with the car turned off and after installation, you start it and you're back in business.

A#7 - The warranty version is a little more expensive . . . 2X $$. <grins> I will test the pedal in my car before sending it. The low price, effectively shipping and something so my wife won't complain about my time is all I'm after. I think Doug's rate was in the same ball park.

Understand that there are wear surfaces involved. Eventually, one of the two variable resistance traces will fail in a way that can not be repaired. If I do the work, I'll have to deal with a part that can't be "cleaned" and returned to service. When that happens, I'll have to replace the guts with something a little more sophisticated. But we can talk about that when it happens.

Bob Wilson

 

<div class='quotetop'>QUOTE(deborawkart @ Jul 20 2007, 10:53 AM) [snapback]482235[/snapback]</div>

Good enough. I'll put the replacement in my car tonight and make sure it works across all speed and power ranges. If it checks out, I'll send you a PM with with the tracking number.

As for "Who are you guys anyway???" The Zen of that question . . .

Bob Wilson

 

Debora, you are right that Bob is amazing because he does so much technical Prius stuff, and was willing to become the 'APA Maytag repairman' when I left for China.

Me I just write endlessly about the car, and figured out (with much help from others) how to address this problem. Fortunately the fix seems to be adequate so far. I just focused on one little Prius problem that no one else was looking at.

For what it's worth, both APA's that I sent Bob had already been tested in my Prius. More or less public knowledge that I was exchanging them for $75. Not too bad for an hour of (fun Prius) work. But I do not set his prices nor warranty terms!

Might be fun to ask Toyota what warranty they offer for their $400-or-so part

Attached picture is a 'hybrid' in Yunnan Province of China. Cross between a rototiller and a trailer. The only Prius here (I understand) are the 2000 or so produced domestically and they are all way up in Beijing. I wish them well, because the fuel here is quite high in sulfur

[attachmentid=9971]

 

<div class='quotetop'>QUOTE(deborawkart @ Jul 20 2007, 10:53 AM) [snapback]482235[/snapback]</div>

I put your unit in my car and drove around town and on the interstate today including all pedal positions. I'm confident it will work just fine and will ship it out tomorrow. Curiously, this required me to change my driving habits since most of my driving uses cruise control. But I understand the 2001 doesn't have cruise control.

I'll include a 10 mm nut-driver, vice grips and photos on how to swap the accelerator assembly. It is fairly straight forward and a lot easier if you have a lawn furniture recliner (the photo will explain.) Alternatively, any mechanic can use the instructions and swap it out in about 15 minutes. I'll include a shipping label and tape so you can put everything in the same box and return it.

In the meanwhile, I'll put Doug's second unit in my car for testing. I've also picked up a couple of failed units and will be rigging up a tester jig. I may investigate other possibilities.

Debora,

Please send me a PM or e-mail or reply to the PM I'd sent before. I'd prefer not to advertise the tracking number and contact phone numbers. Just take out the blanks and fix the punctuation:

b wilson 4 web (at) hiwaay (dot) net

Thanks,
Bob Wilson