Stuttering sound when braking - UPDATED WITH AUDIO

I'm at 75k and still doing it. Dealer replaced my passenger side axle at around 35k and the noise went away but its back. We took a 2013 Plug In on trade with 49k miles and it too was make the same noise. I've driven 3 other 3rd gens and all make the noise but it seems to be only when in regen braking. Will try in neutral to see what that does if anything....it sounded like the brake dust shield rattling at first but the technician that ultimately called for the replacement said they noted some scoring of the shaft when they removed it.

 

I have the same problem. When the car is in N, the noise is go away even thought you brake hard. It happens since the day I lower my prius.

 

Tried mine in neutral today and while turning and no noise. This has to be related to the regen braking.

 

I have the same noise/concern. Working on getting it fixed at this time. It's frustrating and time consuming. One dealer cannot hear it, one heard it but can't diagnose it?! Wth! Heading to another dealer next week. I heard that replacing the axle fixed the problem. I'm in the same boat with expiring ext. warranty nearing. Mine started around 60k and I now have 92k miles.

 

So... I have the official response from Toyota. Its the regen. I made the noise for my dealer and he called it a local toyota official tech and they contacted Toyota and that was their response. So I wouldnt worry about it. Oh and how to make the noise on command?
1. Drive about 25 mph
2. Brake slowly with the steering wheel straight.
3. Then as you are braking turn the steering wheel to 3 oclock position and hold it there.

then CLACK CLACK CLACK.

 

Hey, yeah like others have said it goes away in Neutral. Tried it on a 2015 with 50 miles on it and it does it as well. Will try and get a 2016 and see if I can duplicate it.

 

I can confirm this happens on a 2016 exactly like the clip. I was thinking there is something wrong with my vehicle, had the service manager go for a ride and he said its normal, and that toyota changed something in the regen and it makes this noise. Mine was noticed at around 6k.

 

I'll confirm too that the 2016 does the same thing. It started intermittently at about 25,000 miles and now that I have close to 34,000 on it, it does it all the time. My dealer has a case open with the Toyota Field Tech and they're supposed to come out and take it on a test drive.

 

Update: Replaced both front axles and clicking sound has gone away. Not one click since the repair. It was a battle to get dealer to fix it though. You have to be persistent.

 

Ok, so as to be clear to all of us, what exactly was replaced? When you say axle, do you mean the CV joint? The axle? or both? Or better yet, if you could post a copy of what repair they did (that way we know what part number this entails) that would be great.

 

It was both. CV Axle Assembly replaced on both sides.
Part #43420-47031 $495 Driver's side.
Part #43410-47031 $510 Passenger side.
Description for each-Shaft Assy, FR DR
Labor-around $225 for each.
Total-$1500 ($750 each side)
*Did not drain transmission fluid.

 

ouch.

 

I have the same issue with my 2016. Started about 10k miles in and after a long road trip when I was driving in a hilly region.

 

I also have the same with my 2017 at 28k. I mostly want to hear form people who noticed this long ago if there was any deteriorating of symptoms.

 

I too have this problem. 2017 two. Happens when car is warm or hot, and I notice it with windows down and speed is less than 30mph. Putting it in neutral will make it go away. Car has 50k on it though.

 

Looks like im im the same boat with the clicking sound when light braking at speeds from 30mph down to 7mph. once regen stops and hydraulic kicks in it is silent. if i need axle replacement whats the best oem alternative...$400 bones for OEM is a bit much. Also do i need to replace seal in transmission?

Pixel 3a XL ?

 

Should both axles be replaced or just driver side? recommendation for aftermarket?

Pixel 3a XL ?

 

FYI REGEN Braking........ Theres no regen braking on any Prius using the rotors (discs in UK) or the braking system or are there any "solenoids" on the braking system.

REGEN Braking is a term, it means when the car isn't powering the wheels going forward then the wheels will be doing engine braking and slowing the car down. Engine braking in hybrid cars is called REGEN Braking as the wheels don't turn the engine as the system disengages the engine, this would be like putting a normal car in neutral. However the Prius still slows down when you take your foot off the brake, well when the engine turns off and disengages the gearbox engages the driveshafts to the generator in the gearbox which produces electricity for your battery pack.

So in conclusion the braking system are the same brakes as normal, the "magic" occurs in the gearbox. Having said that when you press the brake extra load is drawn from the generator assisting the brakes but both things aren't linked together they just work together, which will make your brake pads last longer.

The issue is in the Axel Joint or (CV Joint UK) heres what you need to do. Wash out the old Axel Grease (CV Joint Grease UK) of the Axel (CV Joint UK) using Brake cleaner. Make sure its dry which shouldn't take long as it evaporates quickly. Then inject using a needle grease gun fresh Axel Grease (CV Grease uk) into the Axel (CV Joint UK) in and around the ball bearings. Drive the car and if the noise has gone you then know what the issue is. This solution can make the noise go away for up to 15K miles or about a year.

IF you are fitting or having New Axel Joints (CV Joints UK) fitted I recommend asking the mechanic or whoever is doing them to fill the Axel (CV Joint UK) with RED Line CV Grease, its a thicker grease which does not brake down as quick.

This is a very common issue as you'll find a lot of these Axels (CV Joints UK) are always out of stock or low stock.

I bought 2 used Complete Axels (Driveshafts UK) for £50 I packed them with new grease while I waited on both inner and outer Axels (CV Joints UK) to arrive after I could get them. Since fitting complete Axels (Driveshafts UK) the ones I remanufactured its been 50K miles not a clunk or click!

Total Cost including all parts was £170 or $232 there was no Labour costs as I have the tools and do all my own work. A Decent Mechanic will charge you about £150-200 ($200-280) as theres a fair amount of work involved.