Rear axle beam assembly repair

Discussion in 'Gen 3 Prius Main Forum' started by John Lloyd, Nov 28, 2023.

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  1. John Lloyd

    John Lloyd Junior Member

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    I've got a 2010 Prius with 135,000 miles on it that's been running great. I bought it new and it's been well maintained. The other day the wheel broke while parking it. Looking at manual diagrams, it looks like a lower control arm broke. My service garage told me the car would need a new rear beam assembly, and it wasn't practical to repair. I can't find any Toyota recall for the problem, or class action suit on it. Should I bring it somewhere else to have it looked at, or am I basically SOL.
     
    #1 John Lloyd, Nov 28, 2023
  2. bettergolf

    bettergolf Active Member

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    I'd rake it elsewhere, and if something on the frame is broken a body shop may be able to weld it.
     
    #2 bettergolf, Nov 28, 2023
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  3. Leadfoot J. McCoalroller

    Leadfoot J. McCoalroller Senior Member

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    That doesn't usually happen without advanced corrosion. How rusty is this car?
     
    #3 Leadfoot J. McCoalroller, Nov 28, 2023
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  4. bdc101

    bdc101 Member

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    Agreed - if it's rusted out it's probably time to replace the beam axle, and possibly more than that. Did your mechanic not tell you WHY it broke? These things don't tend to break except by excessive rust.
     
    #4 bdc101, Nov 28, 2023
  5. rjparker

    rjparker Tu Humilde Sirviente

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    Junk yard
     
    #5 rjparker, Nov 28, 2023
  6. John Lloyd

    John Lloyd Junior Member

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    The outside body is essentially rust free (just waxed it), but there's considerable rust underneath. But I didn't think it was so bad the wheel would break. I'll upload a photo. IMG_1713.jpeg
     
    #6 John Lloyd, Nov 29, 2023
  7. John Lloyd

    John Lloyd Junior Member

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    Rusty, but I didn't think so much that it would cause this failure.

    Yeah, he said it was rust, but thought it shouldn't have failed like that, and suggested I try to work with the Toyota dealer for some kind of compensation or repair.
     
    #7 John Lloyd, Nov 29, 2023
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  8. John Lloyd

    John Lloyd Junior Member

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    One other note - the garage replaced a wheel bearing on the same wheel three weeks earlier. Could that be related?
     
    #8 John Lloyd, Nov 29, 2023
  9. rjparker

    rjparker Tu Humilde Sirviente

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    Could be. An oem wheel hub would never fail like that but they cost $250-$400 for the part alone. Cheap ones fail quickly. Take a pic with the tire off and some light on the subject.
     
    #9 rjparker, Nov 29, 2023
  10. John Lloyd

    John Lloyd Junior Member

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    Replacing the wheel bearing cost me $675 - wheel bearing assembly $355, wheel speed harness $70, and labor $250. I'll try and get some pictures when I get a chance.
     
    #10 John Lloyd, Nov 29, 2023
  11. Georgina Rudkus

    Georgina Rudkus Senior Member

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    The only repair is to replace the axle beam assembly which is apparently rusted through.

    Rust does not start on the painted surface of the car's body. It always starts underneath.

    This might be a lesson for those who do not believe in rustproofing.
     
    #11 Georgina Rudkus, Nov 29, 2023
  12. bdc101

    bdc101 Member

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    Crazy to think that a mechanic could do all that work and yet not recognize it was structurally about to fail catastrophically. Says something about the mechanic.

    Usually the rust-perforation warranty is much longer than the rest of the vehicle, but at 13 years of age it might not still apply. Regardless would be good to bring up with Toyota.
     
    #12 bdc101, Nov 29, 2023
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  13. Georgina Rudkus

    Georgina Rudkus Senior Member

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    If the axle beam is in such bad shape with rust, the rest of the undercar components are likely in bad shape, too.

    It might be time for a new car.
     
    #13 Georgina Rudkus, Nov 29, 2023
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  14. Mendel Leisk

    Mendel Leisk Senior Member

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    Toyota should hot-dip galvanize the suspension. I looked at ours after a few years, though what the heck is happening, started cleaning and coating everything I could reach, with boiled linseed oil. That's worked out good, but Toyota's rust protection is zero...
     
    #14 Mendel Leisk, Nov 29, 2023
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  15. John Lloyd

    John Lloyd Junior Member

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    The mechanics are very good. I've used them for almost 30 years. They did say they plan to visit this issue, mentioning how some of the old Tacoma's were poked with a screwdriver and declared undriveable.
    I did speak with my Toyota dealer, where I purchased it new. They couldn't offer any help. They mentioned for 'loyal' customers, ie. had all my servicing done at their dealership, that they might go out of their way to make it right.
     
    #15 John Lloyd, Nov 29, 2023
  16. John Lloyd

    John Lloyd Junior Member

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    I've always (except when I was young and poor) bought cars new and driven them into the ground - about 15 years. I've never had a catastrophic failure like this. I've had a couple frame welds, on my '89 Toyota pickup and an old diesel VW rabbit. I always thought the dealer rustproofing was a ripoff, plus newer cars are so much more rust resistant. I need to look into what's being offered for rust proofing these days.
     
    #16 John Lloyd, Nov 29, 2023
  17. John Lloyd

    John Lloyd Junior Member

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    yeah, I got a new car almost two years ago. I've been sharing the Prius with my son, and planning to give it to his sister. :-(
     
    #17 John Lloyd, Nov 29, 2023
  18. Leadfoot J. McCoalroller

    Leadfoot J. McCoalroller Senior Member

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    Could be a trick of the light, but the photo seems to show a lot of wear on the inside edge of the tire tread, suggesting that there's been a problem for a while now.
     
    #18 Leadfoot J. McCoalroller, Nov 29, 2023
  19. Georgina Rudkus

    Georgina Rudkus Senior Member

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    You are correct. They did a shoddy job and sold the warranty.

    The military does a good job on their vehicles. Correctly done, rustproofing is very labor intensive and very effective.

    One that has a good reputation is New Hampshire Oil Undercoating.

    Home - NH Oil Undercoating
     
    #19 Georgina Rudkus, Nov 29, 2023
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  20. John Lloyd

    John Lloyd Junior Member

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    Interesting. I'll have to take a closer look at the tire.
     
    #20 John Lloyd, Nov 30, 2023
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