Headlight level sensor 'tie rod' broken

Can you post a picture? I vaguely recall someone a while cobbled a simple but effective fix, sub'd. some commonly available bits of hardware.

Viability of this approach would depend on what exactly is broken.

 

Another problem with Automatic Headlight Leveling System | PriusChat

That sounds like the "dogbone" link . . .

 

I have one laying around. The "dogbone" joint became stiff so I just replaced it rather than mess with it. It has been sitting in the basement (climate controlled) for about 5 years now. The car that it was removed from (2005 Prius) is still going strong at 338,000+ miles on the original hybrid battery. I can get pictures to you if you are interested. Been six weeks since I've been on the forum due to work obligations. Hopefully, life will slow down again.

 

Does anyone have a measurement of this dogbone link arm please? Mine is broken and I can't find one in a scrap yard. The Uk don't sell the part after market and to get a full one from the US is £200+

 

I'd help you out but third gen it's a different part. One thing you can do: do Google image search for the second gen part number, pick some pictures where it's the most head-on, zoom it as large as practical on screen, measure on screen (just lay a ruler on it) something that is not broken on your, then measure the broken arm. Then do a ratio equation, to extrapolate what the length of the broken arm should be. Try this on two or three different pictures, see how close they correlate.

What I dug up, from McGeorge Toyota (US Toyota parts retailer):

Prius ride height sensors:
2nd gen: Height Sensor - Toyota (89408-47010) ($309.13)
3rd gen: Height Sensor - Toyota (89407-12030) (276.72)

 

Mine is 75mm

Posted via the PriusChat mobile app.

 

centre to centre of linkages?

 

Thank you both for your input. 75mm is good enough for me but I hadn't thought of scaling off a photo, that was a great plan b! Thank you again!

 

You've got to be careful, consider the distortions of perspective, foreshortening, but yeah it kinda works. I was a draftsman and checker in consulting engineering for a lot of years (plus a few in Steel Detailing), and sometimes you've got next to nothing to go on, lol.

 

Finally finished and installed. Thanks for the help

 

I need to change "dogbone" on mine Prius 2007 and I see that you have used generic adjustable variant.
I found this kit from Febest 0123-GRJ120-KIT LINK, HEIGHT CONTROL SENSOR, REPAIR KIT 48906-35010 for about 20-25€, looks very similar to your.
Just to confirm, 75mm is from centre to centre of linkages?

One more thing, I have a halogen lamps H4 on my Prius and manual switch for headlight level in cabine and this auto height control, what is the point to have dual system !?

 

I used 75mm and it's passed a UK MOT (ministry of transport test) it looked "right" when fitted.

I also have a manual hight adjustment in the cabin as well as this system. I suspect that the manual adjustment is for towing or heavy loads in the back where as the automatic sensor is for pot holes in the road surface but that's just a guess.

 

Toyota should add that level sensor to the maintenance schedule. Especially in the salt zone, ignoring it for 10 years is what kills it.

 

Thank you for fast answer. I didn't get any error message in system, just have luck to see broken rod on regular service maintenance (car was on lift).

btw. mine looks like this.

 

Those dang ball joints seize up. Are the roads salted or sanded?

The most direct repair would be a weld, if it's not cost prohibitive.

Our 2010 with LED headlights has similar. I periodically unbolt the end attached to the rear axle, then the linkage can be moved freely, which redistributes the grease.

I also have some spray given to me by the guy that did our garage door opener. It sprays on liquid, then gels. I've put a little in, quite a way back.

The current rust prevention standards are terrible, by the way. They need to galvanized more components, or allow more coatings (some currently banned?).

Too, if they could come up with alternatives for the relentless salt dumping, it would be better for the environment, and also extend car lives, a double win.

 

I don't know, but we in Sweden generally have cold and wet climate and all roads are salted or sanded depending on speed.
My 13y old Prius is rusty around rear axle and rear suspension. Other body parts holds very well against rust...

 

I've have good results coating everything with boiled linseed oil. It seems to just arrest the rust that's there, prevent any further.