Clicking Sound on Regen Braking

Yep, that's pretty much how mine behaved. Hopefully it won't be a reoccurring problem with these, not exactly cheap to fix out of warranty and that being a powertrain item only 60,000 miles.

 

Same problem with my gen 3, (115.000 km) I will try out some different grease for the balljoint, maybe it will shut it up ...

 

My 2017 Prius 3 touring has been doing this for about 2000 miles or so now. It came on relatively suddenly as it didn't happen for the first 25,000 miles or so, but also I can't pinpoint it exactly since when it first started happening it sounded to me like the window was vibrating while stopping or something. But there is no doubt in my mind it is the exact same problem that several(though not all, but most of the complains in this thread) people in this thread have reported.

It sounds just like the videos posted. It only happens during gentle regen braking, not hard braking, not braking in neutral, not just driving normally, not coasting to a stop. It varies with the velocity of the car(it clicks slower the slower the vehicle gets.) I can regen brake and start hearing the noise, and if I let off the brake it goes away completely.

My dealer and all the ones around me are notoriously terrible to deal with, I've had them ruin transmissions in the past with routine maintenance and complete buffoonery like putting 2x as much transmission fluid in, so I have no intention on getting them to work on this. I don't even trust them to change the cabin air filter properly. My main concern is whether this is an annoyance or will constitute a catastrophic problem.

It is not a standard CV joint issue, it does not click while turning, there is no sensation that can be felt, happens no matter the position of the steering wheel.

It also seems like those who get the axle replaced have the noise come back later. To me I wouldn't be surprised if this eventually occurs in all GEN 4 priuses(though it did NOT occur in my GEN 3) eventually and just some people can't notice it, since some people here can't hear it in the videos and I can hear it clear as day in both the videos and in real life(though I know what I'm looking for), and that it came back after replacement. (What are the odds of most people who have had this fixed getting 2 bad axles on a vehicle where most people get zero, seems to me the problem is far more widespread).

 

I just had this pop up on my 2016 with ~34,000 miles on it. Took it to dealer and gave them a video of the noise. They blamed it on gravel in several places so I had to go back and drive it again with them to show them the noise was still there. They called to say that they can't see any actual failed parts but they elevated this to Toyota and were instructed to replace the axle so they're doing it under warranty. Interestingly they say it needs an alignment and quoted me $100 for that. I questioned that since I've done this job on other FWD cars and always needed to re-align the front end after disassembling it enough to replace the axle. They're saying that the Prius is different and the alignment is not required for the repair. Anyone have any experience with that repair on a Prius?

 

Well I had a 2016 Prius that has that issue and they initially did give me the "it's a rock stuck in the rotors" or it's the rust ring on the rotors. I referenced this thread and video showing the same noise the car made. I assume yours was on the driver's side as well?

Alignment.... I don't think a CV axle would require alignment, so I don't think they were wrong about that, whether your car needed an alignment is another story. I usually do that when I get new tires. I don't think this idea of doing an alignment every 15,000 miles is necessary unless you live in pothole hell.

It has been sort of a mixed bag on whether the passenger CV axle starts the same noise. At any rate if it is under warranty get it fixed.

Hopefully the Prime doesn't have this issue...

 

I posted the alignment question in another thread. I'm sure it does need an alignment but my question was why that wouldn't be a required step when disassembling the front end components. Another member with TIS access referenced the instructions and step 13 of 17 is indeed "Adjust Front Wheel Alignment" so I've emailed the instructions to the service writer and I'll see what they say. If I wasn't having to be without my car for a week while they fix a warranty item I'd happily pay for an alignment. Since they're doing this work anyway I'd prefer not to pay $100 out of pocket for something that is a normal step when doing the warranty repair.

 

I don't know why they would try to charge you for what the warranty claim would pay for unless they're trying to double dip... Might want to look for a different dealer...

 

Unfortunately it's the only dealer withing about a 4hr drive in any direction. I didn't buy from them but it's tough to drive that far for service anywhere else. I'll see what they come back with on it and then elevate to Toyota if needed. It just kind of irritates me that they're trying to charge me for something that should be part of the warranty repair. Did I need it anyway? Yes. But to me it would be the same as having an engine problem that required opening the crankcase at the same time that I needed an oil change. Did I need an oil change anyway? Yes, but they're not going to charge me for one when they have to drain and refill the oil to do the repair. On pretty much any vehicle, if you take apart the front end components the instructions tell you to check and adjust the alignment because it will likely be thrown off by the rest of the work.

 

They intend on getting paid from Toyota for doing it, and then getting paid by you to do it. If it is part of the repair procedure on tech info, then Toyota is paying them for it. You are not obligated to pay for it even if it was necessary before the repair.

 

My advice then if you're going to have them do the work would be to dispute it and contact toyota and explain what is going on. I wasn't charged for anything and they shouldn't charge you for anything either.

 

I don't see why it would need aligning after an axle replacement. I've had axles replaced, (or CV joints or CV boots), and they weren't re-aligned afterwards.

If it needs aligning, it must have been out of alignment beforehand.

 

I'm sure you're correct that an alignment isn't needed for the axle replacement. If Toyota is paying the dealer for an alignment as part of the warranty claim then they shouldn't be charging the customer for it either.

 

Yes, but they wouldn't be doing the alignment. And TOYOTA would well know that an axle replacement doesn't need an alignment, so would reject the claim from the dealer.

I'm not sure if the dealer does the alignment themselves - here, some outsource them to specialists.

 

Just going based on what @tjsadler said, assuming what he said is (was) correct. I don't recall an alignment having been done on my '16, so I'm pretty sure Toyota isn't requiring an alignment to be done on the axle replacement, nor would it be mechanically needed. More than likely an up sell. Whether the dealer claims it is needed as part of the warranty work or not...well that's why I suggest a different dealer. I don't like being BS'ed.

Anyway, seems like there is a fair number of axle replacements and on the driver's side specifically, all which are under warranty thankfully. Wonder if anyone with a 2018 model has had this happen yet? Someone would really have to put a lot of miles on theirs though, seems to pop up after 30k...

 

For the record, an alignment IS a required step in replacing the axle according to Toyota and the dealer has now admitted that and is doing the alignment as part of the warranty repair. I wouldn't be surprised if some dealers are skipping this step but they shouldn't be. Any time you take the front suspension apart an alignment is a recommended step because it's easy for something to be slightly off when you put it all back together.

 

Maybe something is different - I've had boots, CVs or, in more cases just a reconditioned driveshaft, installed on Mazda, Suzuki and Nissans - but never a TOYOTA.

 

I'll have to look at the service records and what all they did on my 2016...and then throw all the records out because I don't own it anymore and all that apparently was on the carfax report...

 

Does anybody have any updates as to whether their noise has come back if repaired or gotten worse if not repaired?

 

My noise has not come back and it has been almost 15K miles now on the repaired axle (42K) and I heard mine originally at 6K miles or so.

 

It does. My ‘17 Prime is in the shop right now getting a new driver’s side axle.