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2001 ABS/Brake Alarm & Light

Discussion in 'Generation 1 Prius Discussion' started by lovenrockets, Feb 22, 2009.

  1. lovenrockets

    lovenrockets New Member

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    Hello All,

    I just have a couple of questions and was hoping someone could offer some insight.

    • 2001 Prius
    • 35,240 miles
    • 3,000 mile maintenance for life of car

    1. The brake light came on. Found out the brake fluid was low - from time to time - very infrequent, fill it up with standard brake fluid
    2. Today - ABS/Brake Alarm [very high pitch] went off, but didn't stay on. On/off/on/off...then stayed off
    a. Checked brake fluid (it is at max level)
    b. Drove car a few miles and the brakes were performing at 100%.

    I'm at a loss with what is happening with my car. It appears to be running and braking just as it is suppose to be.

    1. Does anyone have any insight on this?
    2. Could the central alarm be putting off a false alarm?


    Thanks so much,
    L&R


    [​IMG]
     
  2. lovenrockets

    lovenrockets New Member

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    Just to confirm it really does have 35,240 miles on it. It's been a great little car - really a great performer.
     
  3. Patrick Wong

    Patrick Wong DIY Enthusiast

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    If your brake fluid needs to be replenished, then you must have a leak somewhere. If the brake system alarm has triggered, then you must have a serious problem, probably related to that leak.

    Since failure of your braking system would be a significant safety issue, I suggest that you not mess around. If you can't locate the leak, please visit your Toyota dealer so that the diagnostic trouble codes can be retrieved and a diagnosis can be provided to you.
     
  4. lovenrockets

    lovenrockets New Member

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    Hello and thank you for responding,

    There is never any brake fluid on the ground, and fluid is added very occasionally. Perhaps it is burning off? The car is used only for local driving. The greatest distance this car has driven (at one time) in 1.6 years is 45 miles.

    The alarm did trigger but the brake fluid level has not changed in 2 or 3 months.

    The thing which I find to be perplexing is that the brakes are functioning perfectly. There isn't any delay, intermittent response, no noise, etc.


    I did wonder if perhaps it is a random error? I will bring it to the Toyota dealership though. I have been reading the Toyota TIS in relation to this issue in an attempt to trouble shoot this myself.


    I am trying to find the logical path to this warning. The alarm did not sound in the second drive around my neighborhood. This is my daughter's car and I just can't take any chances.
     
  5. Patrick Wong

    Patrick Wong DIY Enthusiast

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    There are basically two reasons for the brake fluid level dropping over time:

    1. As the brake pads and shoes wear, the fluid level will drop
    2. A leak

    How low is the "low" brake fluid level, when you refill the reservoir? With 35K miles on the odometer I would expect the brake fluid level to have dropped maybe 1/8" or 1/4" from the new level, if there were no leaks and assuming no driver error like leaving the parking brake on when driving around, pressing the brake pedal with the left foot while accelerating with the right foot, etc.

    If you have time today to look at the problem, I suggest that you raise up the car, remove the four tires, and carefully inspect the front disc brakes and flexible brake lines leading to the four brake assemblies. Look for evidence of leakage. Also look at brake pad thickness; a new pad is 11 mm thick. 1 mm is minimum thickness (not counting the steel backing plate.)

    Release the parking brake and pull off the rear brake drums. If the drums are stuck, thread a couple of 6 mm bolts into the brake drum holes to force the drum off. Then look at the wheel cylinders to see if those are leaking. Look at drum lining thickness; 4 mm is new and 1 mm is minimum.

    If you don't see any problem there, then the next step is to remove the cowl assembly that runs across the rear of the engine compartment so that you can get a good view of the brake components mounted below the cowl, such as the brake pressure accumulator.

    This will require you to remove the windshield wiper arms, then unscrew the two little screws on both ends of the black plastic cowl cover. Then carefully remove the rubber hood seal that runs along the cowl. The seal has sticky tape on it that is reusable, don't peel the tape off. Gently remove the two-piece black plastic cowl cover so that you don't break the plastic. Then remove the windshield wiper motor and linkage assembly. Unbolt the relay box attached to the cowl tray and remove the wiring harness from the cowl, gently removing the plastic clips from the cowl so that they do not break. Then unbolt the sheet metal cowl and remove from the car.

    Now you will have full access to the underhood brake components. Starting with the brake fluid reservoir, inspect all parts carefully, looking for leaks. Look at all of the steel brake lines.

    If you don't find any leaks, at least you will have looked at the car in detail, and when the dealer tech gives you a diagnosis, you have a better chance of determining whether it is reasonable or BS.
     
  6. lovenrockets

    lovenrockets New Member

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    Hi Patrick,

    Thank you so much for all this detail. I think I can handle this, except I don't have a lift here at my house, just a 2-ton jack. If I am unable to, I am going to print out your post and bring it with me to a service center.

    To be honest I'm a little put off by the dealer repair centers because the sales associates start calling once they get an idea a car is being serviced. It isn't the case each time, but has been so in the past.

    I just took the car out again. The alarm came on right when I turned the car on. It turned off after 5 seconds. I pushed on and off the emergency break, I drove around the block hitting the breaks and then put the car in continuing to drive around the block. I came back turned back on and off the car and the alarm nor lights didn't come on.

    Thanks so much for your help,
    L&Rs
     
  7. Patrick Wong

    Patrick Wong DIY Enthusiast

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    Since you are continuing to get an alarm, it is reasonable to be very concerned about this problem.

    A hydraulic floor jack is enough, you can look at one wheel at a time. If you have two (or four) jackstands, then you can raise up the car and work on one axle (or both axles) simultaneously.

    I think that if you can't figure out the problem yourself, you'll need to visit a Toyota dealer because the braking system is quite unusual and an independent shop not trained on Prius is going to have trouble if the problem goes beyond the brake components in the wheels.
     
  8. lovenrockets

    lovenrockets New Member

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    Hi Again Patrick,

    Thanks so much for all your help. I have pulled off one wheel but got interrupted with something else. I am going to do one by one and also try to get it scheduled as soon as possible.

    I will write back again when I have a solution.

    Thanks again,
    L&R
     
  9. lovenrockets

    lovenrockets New Member

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    Hi Patrick,

    I brought the car in today. They isolated it to two things, neither being brake failure -


    1. One of the computers malfunctioning(?) It is under 100% warranty and they ordered it today....or.......
    2. If it is not the computer, then it is likely an actuator (I did read something about that on the TIS Toyota website yesterday.)

    They reassured me that her brakes would not fail anytime in the near future. They also confirmed that there was not a leak.

    I am hoping it is the computer (For some reason I cannot find the paper they gave me and what codes came up - and I'm searching everywhere for it.).
    The replacement for the actuator be expensive (as I was told). I really do believe they will do everything they can to solve this with item number 1.

    Thanks,
    L&Rs

     
  10. Patrick Wong

    Patrick Wong DIY Enthusiast

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    Thanks for the update.

    Can you estimate how much brake fluid you have added since owning the car? If more than a trivial amount, then it would be hard to imagine where the fluid is going if there's no leak.
     
  11. lovenrockets

    lovenrockets New Member

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    Hello Again,
    We just went to today to get the ECU replaced. This is the exact explanation:


    1. Customer stated check engine light came on - Parts On Order
    2. P0300, C1202, C1251 and C1259 malfunction in the HV ECU
    3. Replaced HV ECU
    4. Cleared Codes
    5. Drove car and no new codes reappeared.
    Parts - #89890-47030/Computer A24

    This repair was covered at 100% warranty which was really shocking to me. The mechanic spent about 3.5 hours today assuring it was working correctly. This is in addition to the original assessment.

    Anyway, we used 3 (pints?) of break fluid that was put in the car since it was purchased October 2007.

    The alarm didn't sound once on our way home. We were told to wait a while to see if the alarm sounds again. They said they believe the ECU solved the problem. If it is not the ECU than they stated it might be an "actuator", but are hoping the ECU solved the intermittent alarm.

    The car now has 36,200 miles on it, is garage kept, no rust, dings and maintained every 3k miles. Do you think we are okay now?





     
  12. Patrick Wong

    Patrick Wong DIY Enthusiast

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    1-1/2 quarts of brake fluid is a tremendous amount of fluid. That is probably 50% or more of the system's total capacity.

    I do not believe that ECU replacement will solve the brake fluid consumption problem, and suggest you keep an eye on the reservoir level. If you start to see it drop again, its time to visit the dealer once more.
     
  13. lovenrockets

    lovenrockets New Member

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    Hi Patrick,

    There might be another issue here. My daughter is a new driver and was heavy on the breaks for a while, sort of like my Mother with her Avalon. I had to teach her to not be so hard on them and to take the foot off the gas to slow down as well. I know this is a little issue, but the car sat for 6 to 8 months before we purchased it. The first owner was ill for sometime and then passed away. He did baby this car, keeping records all the way down to every oil change it has ever had (although it wasn't too many because it had very low mileage). Anyway that is a side note.

    We haven't added any break fluid in a few months now and it is at the normal level. They said just as you said about when the break pads wear, but didn't seem to think there was anything wrong with them.

    Do you think it could be an actuator issue? Why would any of these things fail with such low mileage and being garage kept?
     
  14. Patrick Wong

    Patrick Wong DIY Enthusiast

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    The actuator is a squareish box and has lots of brake lines coming into and out of it. It has been known to fail on occasion. However I have not seen a prior post where so much brake fluid was reportedly consumed, so this remains a mystery.

    Anyway, if the fluid level is stable now, then hopefully the car will perform well for your daughter without further drama.
     
  15. lovenrockets

    lovenrockets New Member

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    Thanks Patrick,

    You know it does trouble me that they never took off the wheels to look at the brakes? Shouldn't they look at the brakes (like you suggested) even thought the codes were saying or suggesting something else? I did mention the brake fluid when I brought the car there, but was lead in another direction.

    The alarm has gone off the last two mornings (30 seconds upon starting it) and then never comes back on the rest of the day? I checked the brake fluid and it is holding the same.

    Again the strange thing about the brake fluid going down when it did, there was never anything ever...not even a spot or stain of fluid on the garage floor. I'm still not comfortable with this.

    The replacement of an actuator is apparently expensive and I'm not convinced it needs to be replaced because a 30 second alarm is sounding. The brake fluid has to mean something.

    Thank you,
    Vera
     
  16. Patrick Wong

    Patrick Wong DIY Enthusiast

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    Hi Vera,

    Since you say the problem returned, I studied your post #11 more closely. I am concerned about the service provided for the following reasons:

    1. Part number 89890-47030 is the traction battery ECU. It is not the hybrid vehicle ECU, which is part number 89981-47063. The traction battery ECU has nothing to do with the braking system problem. So my first question is, did they really replace the traction battery ECU in error or did they just make a mistake when filling out the repair invoice paperwork?

    2. DTC C1202 means that the brake level is low. You know that, since you've been adding so much brake fluid. It is good to see that the system confirmed this problem. So, where did the brake fluid go??

    3. DTC C1259 does point to a problem with the hybrid control system, which implies replacing the hybrid vehicle ECU. If that part hasn't been replaced yet, it needs to be now.

    4. DTC C1251 means that the pump motor for the brake system has failed. Maybe the ECU is causing this fault code to be logged spuriously.

    5. DTC P0300 is a random engine misfire. This might be caused if the hybrid vehicle ECU is not working properly and is loading the engine unduly.

    I'd suggest that you call your dealer's service advisor, advise him/her that you are still getting the brake alarms, and ask whether the hybrid vehicle ECU was really replaced given the part number listed on the repair invoice, or not. If not, then it needs to be replaced now.

    Also they need to inspect all brake components to find out where the 1-1/2 quarts of brake fluid went. DTC C1202 is proof that there's a leak somewhere.

    Does this make sense to you?
     
  17. lovenrockets

    lovenrockets New Member

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    Hi Pat,

    Thanks so much for this reply. I'm so sorry I only just saw it now.

    The brakes completely failed yesterday and it was extremely frightening.

    It is getting towed to Toyota now. The place where it I brought it to initally said it was having complete ABS failure or ABS module has failed. They also said they put fluid in the car and it came right out. I'm so upset. I am going to call back Toyota now because it is on its way there.
     
  18. lovenrockets

    lovenrockets New Member

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    I don't understand how a Toyota with extremely low mileage could be having such total failure when it has been babied and garage kept. Now I'm wondering if I should have went ahead and bought her a brand new Corolla last year.
     
  19. lovenrockets

    lovenrockets New Member

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    Patrick,

    I looked up those two part numbers - 89890-47030 and it is a Computer Assy - H.v. supply 2001 per https://www.trademotion.com/shoppingcart/index.cfm?action=viewCart&siteid=213804 and the 89981-47063 is a module.

    It appears that both are used on a 2001 Prius? Is the first one a full assembly and the second a module in the assy? If this is the case, wouldn't the module be replaced within the "entire" assembly?

    Thank you,
    L&Rs
     
  20. Patrick Wong

    Patrick Wong DIY Enthusiast

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    Hi Vera,

    89890-47030, the traction battery ECU, is located within the traction battery metal case located behind the rear seat, within the trunk. 89981-47063, the hybrid vehicle ECU, is located below the dashboard, on the passenger side under the carpet.

    The two ECUs perform different functions. The traction battery ECU keeps track of the battery state-of-charge while the hybrid vehicle ECU takes driver commands via the accelerator and brake pedals. It then decides how much power is required from the gasoline engine and from motor generator 2, and how much regen braking is done vs. friction braking.