2010 Prius ABS Brake Booster & Pump Assembly Warranty ZJB

Old news, was posted by jackthenarrator already.

#searchfeaturedeletemod

 

The wording is similar to a letter we got from Toyota Canada in the last week. Good they're acknowledging an issue, only wish the extension was a bit longer.

Excerpt from your attachment, the US version:



The CDN version that came in the mail:

 

thanks! i have jack on 'ignoramous'

 

Q:

How can a safety defect in a braking system resulting in a specific DTC code (C1256) result in a Preventative Safety Recall (D0H) in which Toyota pays to replace the defect component before it fails but a defect in the braking system of the same model year Prius (2010) that could result in the same DTC code (C1256) result in a post-brake failure warranty repair (Warranty Enhancement ZJB)?

"ABS, BA, TRAC, and VSC control prohibited"? "Braking force solely generated by driver"?

Safety Recall D0H Technical Instructions - pg. 2 (DTC C1256)
ZJB Warranty Enhancement - pg. 1 (DTC C1256)

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Last Modified: 11-3-2017 6.8:8.0.48 Doc ID: RM000000Y3M01BX

Model Year Start: 2010 Model: Prius Prod Date Range: [04/2009 - ]

Title: BRAKE CONTROL / DYNAMIC CONTROL SYSTEMS: ELECTRONICALLY CONTROLLED BRAKE SYSTEM: C1256/56; Accumulator Low Pressure; 2010 MY Prius [04/2009 - ]

DTC C1256/56 - Accumulator Low Pressure

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Last Modified: 11-3-2017 6.8:8.0.48 Doc ID: RM000000XGF012X

Model Year Start: 2010 Model: Prius Prod Date Range: [04/2009 - ]

Title: BRAKE CONTROL / DYNAMIC CONTROL SYSTEMS: ELECTRONICALLY CONTROLLED BRAKE SYSTEM: FAIL-SAFE CHART; 2010 MY Prius [04/2009 - ]

FAIL-SAFE CHART

1. FAIL-SAFE FUNCTION OF CONTROL SYSTEM

(a) When a malfunction is detected in the brake control system, the skid control ECU turns the ABS warning, brake warning / red (malfunction), brake warning / yellow (minor malfunction) and slip indicator lights come on, as well as prohibits ABS, BA, TRAC and VSC operations.

(b) If the skid control ECU detects that a system related to the hybrid control system is malfunctioning, it will prohibit operation of the TRAC and VSC system in order to prevent further malfunctions and to protect the system.

ITEM

OPERATION

Malfunction in the ABS system - ABS, BA, TRAC and VSC control prohibited

Malfunction in the BA system - ABS, BA, TRAC and VSC control prohibited

Malfunction in the EBD system - ABS, EBD, BA, TRAC and VSC control prohibited

Malfunction in the TRAC system - ABS, BA, TRAC and VSC control prohibited

Malfunction in the VSC system - ABS, BA, TRAC and VSC control prohibited

2. FAIL-SAFE FUNCTION OF HYDRAULIC SYSTEM

(a) If a malfunction is detected in the brake booster with master cylinder (skid control ECU or brake actuator) or an individual sensor, control will be stopped and brake effort will be generated by the brake booster with master cylinder (hydraulic brake booster).

(b) If brake control is stopped due to a malfunction in the hydraulic pressure source, the pressure generated in the master cylinder by the driver is applied to the wheel cylinders to ensure braking force.

ITEM

OPERATION

Skid control ECU malfunction - Brake booster with master cylinder (hydraulic brake booster) generated braking force

Hydraulic pressure controlling components malfunction - Brake booster with master cylinder (hydraulic brake booster) generated braking force

Power supply components (Hydraulic pressure source) malfunction - Braking force solely generated by the driver

 

Thank you for sharing this.

Checked with the local dealer this morning. There is a huge backorder of the part needed to fix this issue. They have two 2010 priuses sitting in the service department, waiting to be repaired. The parts were ordered 2 weeks ago and no news on when those will be available...

 

simple, the limited recall turned out to be too limited and instead of recalling all the other cars, it's cheaper for toyota to fix it when it breaks, especially for older cars that are being phased out from service (accidents, theft, auctions, etc). I'm sure the NHTSA allows for that? I've seen other carmakers doing that.

 

Just got my "Customer Support Program Notification - ZJR" today about this. I don't have any warning lights or codes, but I do have the noises, sticky brakes and other symptoms others have noted.

 

Greetings Members,

Can a defective brake booster/assembly cause the master cylinder to fail? I have a 2010 Prius and my master cylinder failed with 83,000 miles on it. I thought this was odd especially since the failure was basically identical to the recall notice for the 2010 Prius under a certain production period, unfortunately, mine was just out of that time period covered and I paid a hefty $3,000 repair for a new one.

It was also explained to me the reason my master cylinder failed was because of maintenance, although under recommendation by the dealer's service department, the brake system was flushed and refilled at 60k and 75k miles.

Any advice would be appreciated.

Thanks,
Claude

 

i had a prius which i purchased to resell. When i first looked into this ABS thing it was like certain production month or something. Because a little while back when i checked 2 different priuses that i owned on the toyota website, one said it was eligible and one said it wasnt.

either way, the one i bought to resell , they covered it. but it took them almost 1.5 weeks to finish it up. Besides mine, there was another one that just got dropped off before me. From what i understand, The dealers are not allowed to "Stock" the parts for the recall. They have to order them as they come in for repairs.

 

The terminology is confusing, and also the way the assemblies are grouped and separated is different in different Prius generations.

In a Gen 3, the "brake booster assembly" is the "master cylinder". And also the "actuator" and the "skid control ecu".

Meanwhile, just beneath it, the "brake booster pump assembly" (one tiny word different!) is a separate part....

-Chap

 

Complaints on NHTSA's safercar.gov website about Generation 3 Prius brakes on years that are not covered by the ZJB warranty enhancement or any safety recall (A0B, D0H):

November 1, 2018 NHTSA ID NUMBER: 11144698
Components: SERVICE BRAKES
NHTSA ID Number: 11144698

Incident Date October 28, 2018

Consumer Location SULLIVAN, IN

Vehicle Identification Number JTDKN3DU4C1****

Summary of Complaint

CRASHYes

FIRENo

INJURIES0

DEATHS0

I WAS TRAVELING NORTH ON THE HIGHWAY. I WAS GOING BETWEEN 50 AND 55 MPH WHEN THE TRAFFIC LIGHT TURNED TO YELLOW AND THEN TO RED. WHEN I APPLIED THE BREAKS NOTHING HAPPENED. MY VEHICLE ACTUALLY APPEARED TO SPEED UP. I RELEASED THE BRAKE THEN PUMPED THE BREAK TWICE THEN AGAIN APPLIED THE BREAK, THIS TIME STOMPING HARDER AND WITH BOTH FEET. MY VEHICLE DID NOT STOP OR EVEN SLOW. I WENT THROUGH THE LIGHT, RESULTING IN A CAR ACCIDENT. I T BONED ANOTHER CAR.

1 Affected Product
Request Research (Services fees apply)


October 30, 2018 NHTSA ID NUMBER: 11144185
Components: SERVICE BRAKES
NHTSA ID Number: 11144185

Incident Date October 30, 2018

Consumer Location TAMPA, FL

Vehicle Identification Number JTDKN3DU4C5****

Summary of Complaint

CRASHNo

FIRENo

INJURIES0

DEATHS0

BRAKES FAILING, GETTING A C1391 CODE, LEAK IN ACCUMULATOR. TOYOTA HAS A WARRANTY ENHANCEMENT FOR THIS ISSUE ON THE 2010 MODEL BUT IT HAS NOT EXTENDED TO 2011 OR 2012 MODELS. I CONTACTED LOCAL DEALER AND NATIONAL REPRESENTATIVES AND WAS REFUSED ANY ASSISTANCE FROM TOYOTA. THIS ISSUE HAPPENED TWICE OVER THE LAST TWO DAYS, BOTH TIMES WHILE VEHICLE IN MOTION ON A CITY STREET. WARNING LIGHTS CAME ON AND ALMOST NO STOPPING POWER.

1 Affected Product
Request Research (Services fees apply)

November 2, 2018 NHTSA ID NUMBER: 11144888
Components: SERVICE BRAKES
NHTSA ID Number: 11144888

Incident Date October 17, 2018

Consumer Location PALM HARBOR, FL

Vehicle Identification Number JTDKN3DU1B0****

Summary of Complaint

CRASHNo

FIRENo

INJURIES0

DEATHS0

BRAKE ACTUATOR FAILURE. ABS, TRACTION CONTROL, AND BRAKE LIGHT ALL ON DASHBOARD. THE CAR HAS NO REGENERATIVE BRAKING. ISSUE OCCURED RANDOMLY WHILE IN MOTION.

1 Affected Product
Request Research (Services fees apply)

October 29, 2018 NHTSA ID NUMBER: 11143620
Components: SERVICE BRAKES, ELECTRONIC STABILITY CONTROL
NHTSA ID Number: 11143620

Incident Date October 28, 2018

Consumer Location VALRICO, FL

Vehicle Identification Number JTDKN3DU6B0****

Summary of Complaint

CRASHNo

FIRENo

INJURIES0

DEATHS0

BRAKE ACCENTUATOR FAILED - NO WARNING AND TRACTION CONTROL/BRAKE LIGHT/ABS WARNING LIGHTS ALL ILLUMINATED. HARD BREAKING TEST @25 MPH CONFIRMS ABS NOT WORKING (I.E. TIRES SKID) AND BREAKING DISTANCE ADVERSELY IMPACTED FOR NORMAL BRAKING. HYBRID SYSTEM CHARGING FROM BRAKING IS DIMINISHED.

1 Affected Product
Request Research (Services fees apply)


October 30, 2018 NHTSA ID NUMBER: 11143936
Components: SERVICE BRAKES
NHTSA ID Number: 11143936

Incident Date December 4, 2017

Consumer Location NAPLES, FL

Vehicle Identification Number JTDKN3DU2C1****

Summary of Complaint

CRASHNo

FIRENo

INJURIES0

DEATHS0

BRAKE ACTUATOR /MASTER BRAKE CYLINDER BROKEN, SAME ISSUE AS PREBIOUS MODELS OF THE PRIUS.

1 Affected Product
Request Research (Services fees apply)

 

Just had the 4 lights come on for the second time this year. First time I just cleared it using a paper clip. Following month I got this Toyota notice about fixing the booster free. I was like great now I don’t have the problem. Well last week it did. Got the car back yesterday all fixed no cost. My car kept making that whiny noise before every 5 seconds. In and out of the car. First thing yesterday, no noise at all. So happy i didn’t have to pay 4K!

 

Hi everyone, I have the exact same problems as described in this post. I went to the local dealer and after a diagnosis, they told me the problem was an abs sensor on one wheel that has to be replaced. Can an abs sensor cause all the problems described here? I have the 4 lights on my dash (abs light, traction light, and both of the !), the break pedal is not « firm » and there’s not regeneration while I break. I don’t want to pay a few hundred dollars to fix this to find out that the real problem is not fixed.

Thanks!

 

The flowchart here starts with "how do you feel about your dealer?".

Just from having the same 4 lights on your dash, and the symptoms of inhibited ECB, we can't say for sure whether you're having the same problems described in this thread or not. You're only describing symptoms that can be shared by a lot of problems, and to pin down what the problems are requires reading the trouble codes.

If you trust your dealer to read the codes and make an educated diagnosis, and their DX is the ABS sensor, then go ahead and have them fix that.

If you mistrust the dealer, the best way forward is probably to set yourself up with Techstream, read the trouble codes you have, and post them here, so we can see if you're having the problems in this thread, or something else.

Moving to the "other posts I must have missed at the time" department:

The answer is that C1256 is not quite as "specific" a DTC as you're thinking it is. It only means the hydraulic pressure isn't building up as fast, or holding as long between pump runs, as expected. It doesn't pin down why. (You can even make a C1256 get logged, in a car with no problem, just by pumping the brakes a bunch of times faster than the pump can keep up.)

The recall stems from certain runs of defective parts that were made and installed in certain runs of cars, where the defect is known likely to lead to a C1256. So you recall those cars and fix them, and if they've already shown a C1256 you take care of it, assuming the defect was probably the cause. (In some cases, you might be able to prove the code resulted from something else, but you probably take care of it anyway, because the proof would be hard and make you look evil.)

You don't necessarily make the same offer for cars built without the bad run of parts.

But maybe later, you also find that even parts without the defect are wearing out sooner than your customers would like, and that can also lead to C1256. You never promised the parts would never wear out, and everybody knows everything one day does, and that's why you only guarantee stuff for three years. But you like your customers to be pleased with their purchase, and the part is a big ticket when it wears out, and you were hoping it would hold up longer, so you do a warranty extension. I've seen Toyota do this on other things before. They did it with the Gen 1 steering rack, and I benefited from it: I got a brand new steering rack eight years and 150,000 miles past the end of the original warranty.

It's like you're a house builder, and you've learned that you bought 100 bad electrical panels that could start fires in your customers' houses. You go to those 100 customers and fix their panels. If they've already had fires, you take care of them (unless maybe it's really obvious something else started their fire).

But you aren't necessarily volunteering a payout to every other customer who ever bought a house from you, who has a fire start for any reason.

 

I have a 2012 Prius III, with 91k miles, that is experiencing the ABS, traction control, etc. lights on. I took it to the dealer and after a $90 diagnosis, the tech recommended replacing the master cylinder and ABS actuator assembly for over $2400. The codes they read are "internal errors" in the unit. It looks like I will need to go through the same ordeal with Toyota to see if they will cover this.

Thanks to all who posted good information on the CSP ZJB extended warranty. I looked through the repair instructions and they differentiate between accumulators that require replacement or not (see attached picture). I'll check mine in the morning if it matches the one requiring replacement.

 

I checked and I have the good accumulator. I also called up Toyota corporate to complain and see what they can do with this accumulator going bad. They were supposed to get back to me Friday, so I'll have to bug them this upcoming week.

As part of my research, I looked up the part for the accumulator (47070-47060) on 1/25/19 and got prices on several dealership parts websites. Then the next day, Saturday 1/26/19 I checked again and Toyota had pulled these parts off the market saying they were discontinued (see the images). I wonder what's going on here??? Are they preparing for a recall?

 

A couple days ago, the traction control, ABS, brake system warning, and brake lights turned on on my 2010 Prius immediately after getting an alignment done. I also lost regenerative braking. I tried asking the alignment technician, but he didn't seem to know what was going on either, so I went to a local mechanic's shop. The mechanic shop told me that my master cylinder was going bad, and mentioned errors regarding calibration and a linear valve.

I just dropped off the car at the dealership to have it checked. I asked them a few times about any brake system recalls, but they repeatedly told me that there were no recalls for my car... Anyone able to chime in here?

 

For sure tell them about the alignment; it's a very odd coincidence.

 

You think so? The mechanic shop guy actually told me not to mention the alignment. I'm thinking if I do tell them, then they may try to blame it on the alignment place, rather than giving me the possibility of repair under the recall program