Brake Actuator Problem

Red,

A chirp when pressing the brake is a known problem and is covered in a TSB. It is caused by air bubbles in the hydraulic fluid and often can be fixed by bleeding the brakes (can only be done with special Toyota equipment). If the air is getting in at the actuator due to leaking seals, the actuator must be replaced (and yes that is an expensive job). Let the second dealer re-diagnose the problem and do the bleeding since that should be a short (1 hour or less) job. If that doesn't fix the chirp, they should then replace the actuator for you under the warranty.

I would not trust the result from the first dealer either (and would not use them again), but the second dealer seems to be taking a reasonable position. You may be escalating too soon.

JeffD

 

Hey all, I have the same problem with my 2007 Prius. It's a year old, and I took it to the dealer service and they had to look the problem up b/c it hadn't happened before here in Lexington, Kentucky.

When they determined it was the brake actuator, they said they would order the part and replace it, covered under warranty. I think that's fair. So yes, I would complain too.

Not sure if it makes a difference, but my dealer service is the same dealer where I purchased the car.

 

Had problems with noise in 2005 Prius after 2+ years and 18000 miles. Brake actuator was replaced under warranty. Had similar problem again after 1+ more years and 32000 total miles. Car out of warranty and replacement part was also beyond its one year warranty. Was quoted $2550 for the repair (over $1900 for the part). Complained to Toyota customer service. The best they would offer is I should pay $600. I think is an outrageous failure rate for a part that is so expensive. It should be under at least a 3 year warranty, parts and labor, any time it is replaced. This repair is discussed in Toyota's Technical Service Bulletin BR001-07 which limits correction under warranty to a customer's specific complaint.

 

We have a 2007 Prius and just recently developed the issue. Had the brakes bled only to make the issue worse. The dealer said Toyota would cover half of the replacement costs...obviously there is an issue here...Toyota obviously knows about it...frustrating to have this with a Toyota. I have had four Toyota so far in my life...did they just mess up with the Prius?

 

i guess your out of the warranty coverage? if not it should be completely covered.

 

If we are still talking about the brake chirp problem, this has no effect on the safe functioning of the brakes - see attached TSB. If your car is out of the 3 year / 36 month warranty, there's no reason for you to incur the cost to replace the brake actuator unless you are bugged by the sound.

I've recently noticed that my 2004 produces this chirp intermittently, especially at high elevations. I don't plan to take any action since there's no safety issue.

 

Pat

At high elevations any air in the system will expand (due to low air pressure) and the chirp will get more prominent. Just bleed the right (passenger side) brake.

JeffD

 

I just did our first one last week and it really wasn't bad. The attempt at bleeding before resorting in replacement of the actuator didn't have any effect. The instructions for the replacement are a bit overkill for even a remotely capable Prius certified tech. The worst part of the job is the bleeding procedure afterward just because of the time involved. I took about an hour and a half longer than the time on the TSB just to make sure everything was correct, my next one will easily be faster without sacrificing quality. If you're close to southern WV come on in we'll replace it for you!

 

If you were only closer to the MD line i would take you up on your offer. I am still trying to convince my dealer that the noise is not my brake pads slipping and is fact due to the brake actuator. I dont know where they come up with this stuff.

 

Shoot!! I had a tech. rep listen for the sound and we did hear it. He said it was something that kept the brake fluid pressure up and was not a problem. I did complain about this while under warranty, just. It's now out of the basic warranty and the noise is back, now louder. Can/should they fix it for free, or do I have to pay for replacing the part??

 

I think if a customer has written proof of complaint not resolved during warranty period then it would be difficult for the dealer to refuse warranty repair soon after expiration. Good luck!

 

PW
2000 miles into my '07 i have dtc C1365 and warning buzz along with ABS VSC lights. Will air in the system throw this (accumultor pressure sensor)dct?

 

This is an interesting one. DTC C1365 "Malfunction in ACC Pressure Sensor".

The accompanying text in the Toyota repair manual says that the DTC may be output if the accumulator pressure drops due to frequent braking (this is not a malfunction). Otherwise, the brake actuator assembly or the skid control ECU are the suspect areas.

I suggest that you reset the DTC, then see if the problem reappears. If it does then you'll need to identify the failed part. I wouldn't suspect air in the braking system unless you have reason to believe that air was introduced from recent brake work.

You can reset the DTC by jumping terminals 4 to 13 in the OBD-II connector, then make the Prius READY and depress the brake pedal 8x in five seconds.

The OBD-II terminals are numbered starting from the right. So terminal 1 is in the lower right, terminal 8 is in the lower left. Terminal 9 is in the upper right, terminal 16 is in the upper left.

If you decide you have a problem and want to DIY I recommend you obtain repair manual info at techinfo.toyota.com

If the brake actuator assembly must be replaced then you'll need access to the Toyota diagnostic laptop to be able to bleed air out of the hydraulic brake plumbing. Probably better to entrust that to the dealer.

 

You are very good
I had air suspitions because i had a front end collision that I did replace the bracket onder the asb pump....the lines were all off
will clead dct and see what arises T Y
MJB

 

Now its back really loud. I looked for 'written' proof of my complaint, i have none. I'll check with the dealership but i'm sure they don't have one either. I could get really lucky if they remember and agree to cut some kind of deal. The 'jumper' fix is interesting.

 

Actually, according to the Bentley repair book, it says to "Turn the hybrid system ON (IG-ON, READY indicator not illuminated)".
Just wanted to clear things up...
And you said 'if the problem disappears...' did you mean the DTC, or the noise??

 

The Toyota repair manual says "Turn the power switch ON (READY)". Try it one way and if it doesn't reset, try the other way.

I was responding to km1159 who had the brake warning buzzer as well as DTC C1365 and brake warning lights. If his problem persists, then he would have to identify the failed part or else decide whether his car has air in the brake lines resulting from the collision repairs.

 

This is the first time I post so not knowing how the thread works. I have a 2007 Prius and I lost the remote key. I called a locksmith in NYC and he unlocked the car, cut a duplicate from a new remote (I think he got it from the dealer) He then tried to program the remote but was not able to. He then plugged a computer into some wires underneath the steering wheel. The moment he did that, the VSR, ABS, (!) and brake light all came on. I took it to a Heritage toyota in Burlington and they told me they need to replace the brake actuator. The part is $1700+ and plus 5 hours labor. Could the lock's smith computer really do that kind of damage? What are my options. Thanks for the help.