Is there a step by step for ABS module replacement & Rotors and Pads Replacement?

I have a 2005 Prius that currently is having Brake Issues. Here is the Story....

01/2017 note: Front Brake Pads were replaced before making a major move. Not by Toyota but a local repair shop that told me they did them before with no problems. (Might be part of the issue so noted with photos below)

10/2017 - Brakes stared acting strange and grabbing, not making for a smooth stop. No Error Codes used some brake cleaned on the front rotors seem to help a lot at the time.

12/2017 - Brakes stared acting strange again and grabbing Lasted for about a week then the follow lights came on, BRAKE light Came on with the ((!)), ABS , VSC. The TechStream Codes were: C1252, C1256 & B1421.

Goggle the problem and discovered the Warranty Enhancement Notification - ZG1. Took to Stokes Toyota on 12/11/17 and was just in the coverage program for this Notification and the BRAKE ACTUATOR was replaced. Completed on 12/12/2017.

07/05/18 - I took the car in for Service of a Oil Change and Tire Rotation and asked if they could check the brakes as they were staring to grab again like they did just before taking it in 12/2017.

After 8 Days time the follow took place:

Was told it was the BRAKE ACTUATOR again and they would replace it under the warranty as it was new in 12/2017. They offer me a free rental car/van while they were waiting on the part to come in. It was delayed a few days and when installed, said it was ok, but I then got a call stating that the Service manager wanted to see if they could find why it went out again and after a few more days, was told that it was not the BRAKE ACTUATOR, but it was a Computer Part #89981-47390 the Hybrid Computer and it could be replaced at a cost of 825ish. I then contacted Toyota Customer Care and they got involved and told me there has not been anything on their side showing that the Hybrid Computer could have caused this problem. So I declined replacing the Hybrid Computer for the time being. Got my Car back on 07/13/2018. I was also informed that the BRAKE ACTUATOR was NOT replaced as it was not bad at the time. The car worked fine, Brakes were ok. So I picked up my car and had no problems until 07/24/2018 when the MAINT REQD Light came on. I drove home. Codes dealer read were C1247 & 179? or 1179 (never seen this one sounds made up)

07/25/2018 Started up the Car today and it is back to the follow lights on, BRAKE light Came on with the ((!)), ABS , VSC. and the Brakes are working as they were back in 12/2017 just before the BRAKE ACTUATOR was replaced. TechStream Codes now of: C1247 (Stroke Sensor), B1421 (Solar Sensor Circuit (passenger Side) & B1271

I tested the STROKE SENSOR and the Voltage was right using TechStream software when not pressed and when pressed.

This time they Told me it was the ABS CPU Part# 895540-47130 and needed to be replaced as a 1st step in diagnosing the problem at a cost of 2040+440(labor)+198(tax)=2682.36. and they probably would also need to replace the 1st diag part at another 825.00.

Ok that's the History now what I have planed and need help with!

I Took some photos of the front Rotors and Pads and they are pretty messed up. Rotors and new pad set ordered from 1A Auto - 2004-09 Toyota Prius Brake Kit Nakamoto CD822, 31377 - 1ABFS02462 at 1A Auto.com

I plan on replacing this this week when they arrive. Should have done sooner I know. I also found using the Toyota/Lexus electronic parts catalog TOYOTA PRIUSNHW20L-AHEEBA - ELECTRICAL - ABS VSC | Japan Parts EU that the Part of the ABS CPU originally was 89540-47080 (08/2004 - 11/2005) NOT the 89540-47130 they claim. When I pull mine I will see its exact part number - I order in off ebay 89540-47100 that I see is interchangeable with 47130. Maybe the 47130 is what they now suggest to replace the original 89540-47080 that japan-parts.eu shows came with my car.

In replacing the Rotors and Pads - The keys parts are to 1/ disconnect the battery. AND Make sure the Key Fobs are no where near the car but should be easy. The Current pads that were replaced in 01/2017 should have also had the Rotors Turned or Replaced at the same time as the Previous Pads seems to have worn down and scraped the heck out of the Current Rotors. So I figure since the rotors should be replaced and the Kits are pretty price effected at only 61.95 for 2 Rotors and 2 Sets of Pads. I would pay that about for just one rotor locally. Is there Anything I need to do after these are replaced with TechStream?

In Replacing the ABS CPU 89540-47100 (since it is less then 40.00 on ebay I figure it worth a shot and have one on the way that is returnable within 30 days with free ship back. That is if the Rotors/Pads do not fix the Brakes Problem) - is this PLUG and Go? I have TechStream v12. Do I need or should I RESET MEMORY and then do the LINEAR VALVE OFFSET when finished?

Many MANY Thanks - I post the lead up to this as this might not completely solve my brake problems! Thanks for Reading and any input would be VERY Grateful!

These are the best photos of the Front Brakes I have taken. The Build up on the pads must be from the Brake Cleaners Use I figure. (the are attached in larger formats too)

 

I'll have it up and the wheels off tomorrow and will make sure the "caliper pins/boots and the caliper piston boot" are lubed good. Thanks!

 

The caliper pins/boots and the caliper piston boot are all lubed good. They slide as expected. Rotor/Pads do not look that bad at all when pulling the wheel, lots of miles left on them. So I guess the next step is to replace the ABS module. I have one that should be here tomorrow.

Is there any special tricks to replacing this? ABS module - 89540-47100
Does it need to be grounded in a test to see if the Brakes problems go away like if I unplug the 4 Plus in the OLD one, leave it where it is, plug in the new one and let it hang temporary where the Glove Box is? Just for testing sake.

I presume that the Unit needs to have the Memory erased using TechStream, and then the LINEAR VALVE OFFSET run after the replacement ABS module is hooked up.

Is there anything else needed?

Many thanks!

 

We lubed today using "Permatex Ultra Disc Brake Caliper Lube" from Advanced Auto Parts. They did not have the 3m version but told me it was the best they carried. I also went ahead (with 12v Battery unhooked, keys inside) Unplug the Skid ABS Module, and Sprayed it lightly on the pins and connectors with "CRC QD Electronic Cleaner" It dryed while we Pulled Tires, and re lubed the Pins.

On Firing up the car (reconnecting the 12v) starting up, the lights all stay on for like 15-20 secs then they all went off. No Lights, Tested brakes - seemed much better. Will run Techstream and just do a health check and see what it finds if anything. But currently it seems like normal again. A few days of driving will really tell as I drive 200-400 miles a day when working.

BIG Thanks on the Lube - I will not believe that was the cause of this mess for a few days

 

Ok Boy, back to the follow lights on, BRAKE light Came on with the ((!)), ABS , VSC.
Read Codes and they are C1247 - Stroke Sensor and B1421 on AC - Solar Sensor Circuit (Passenger Side)

Is there a procedure to Re-Calibrate the Stroke Sensor??