2004 Toyota Prius—NHTSA Recalls, Service Bulletins, & Defect Investigations
Search results for the Toyota Prius 2004, dated January 11, 2009, from the Office of Defects Investigation (ODI), National Highway Traffic Safety Administration (NHTSA), U.S. Department of Transportation (DOT).
- Safety Recalls Updated; 12/5/09
- Technical Service Bulletins Updated; 12/5/09
- Defect Investigations
Safety Recalls (4 records; here, most current first)
12/5/09Component: Vehicle Speed Control: Accelerator Pedal
Potential Number of Units Affected: 4260319
Summary: Toyota is recalling certain model year 2004-2010 passenger vehicles. The accelerator pedal can get stuck in the wide open position due to its being trapped by an unsecured or incompatible driver's floor mat.
Consequence: A stuck open accelerator pedal may result in very high vehicle speeds and make it difficult to stop the vehicle, which could cause a crash, serious injury or death.
Remedy: Toyota filed an amended defect report on November 25, 2009, stating that dealers will modify the accelerator pedal and, on certain vehicles, alter the shape of the floor surface under the pedal. These changes address the risk of pedal entrapment due to interference with the floor mat. redesigned accelerator pedals will become available beginning in April 2010 and dealers will replace any modified pedal with the new pedal if desired. Also, dealers will replace any genuine Toyota or Lexus all-weather floor mats with redesigned all-weather mats, or repurchase the previous mats from owners who do not want the new ones. Additionally, software modifications will be installed on Camry, Avalon and Lexus ES 350, IS 350 and IS 250 models that will ensure that the brake overrides the accelerator in the event both brake and accelerator pedals are applied. Toyota will begin mailing letters to owners in December 2009. Owners may contact Toyota at 1-800-331-4331, Lexus at 1-800-255-3987.
Notes: Owners may also contact the National Highway Traffic Safety Administration's vehicle safety hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov.
Component: Steering: Electric Power Assist System
Potential Number of Units Affected: 170856
Summary: The intermediate shaft and sliding yoke in the electric power steering system can crack when large forces are applied and the connection may separate or the sleeve may fracture.
Consequence: This could result in a loss of steering control of the vehicle.
Remedy: Toyota will replace the steering intermediate shaft and inspect the sliding yoke and replace it if necessary. The recall began on June 9, 2006. Owners may contact TOYOTA at 1-800-331-4331.
Notes: Toyota recall no. 60C. Customers may also contact the National Highway Traffic Safety Administration's vehicle safety hotline aT 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov.
Component: Air Bags
Potential Number of Units Affected: 133
Summary: On certain vehicles, due to improper assembly of the air bag inflator, which is used in the side air bag, the curtain shield air bag, and the knee air bag assembly, some inflators were produced with an insufficient amount of the heating agents necessary for proper air bag deployment. In this condition, the expansion force of the gas may be insufficient to properly inflate the air bag when the SRS system is activated during a crash.
Consequence: This may increase the risk of injury to the occupant in the involved seating position in the event of a crash.
Remedy: Dealers will replace the specific SRS air bag. The recall began on April 6, 2006. Owners may contact Toyota at 1-888-270-9371, SCION at 1-866-548-1851, or Lexus at 1-800-255-3987.
Notes: Toyota recall no. 60B and Lexus recall no. 6LB. Customers may contact the National Highway Traffic Safety Administration's vehicle safety hotline at 1-888-327-4236 (TTY: 1-800-424-9153); or go to http://www.safercar.gov.
Component: Exterior Lighting: Brake Lights: Switch
Potential Number of Units Affected: 183090
Summary: Certain passenger vehicles may be equipped with an improperly designed brake light switch. A silicon oxide build-up occurs on the contacts inside the brake light switch, which can make it inoperable.
Consequence: If the switch is inoperable, the brake lights will not illuminate and can increase the risk of a crash.
Remedy: Dealers will replace the brake light switch. The recall began during December 2004. Owners should contact Toyota at 1-800-331-4331.
Notes: Toyota recall no. SSC 40/Lexus recall no. SSC 4LH. Customers can also contact the National Highway Traffic Safety Administration's auto safety hotline at 1-888-DASH-2-DOT (1-888-327-4236).
Technical Service Bulletins (ODI results list 47 records; the second one here, TSB-0088-08, was duplicated)
12/5/09Component: Electrical System:Battery
Summary: Toyota: Some vehicles may exhibit a M.I.L. on condition with one of more of the following diagnostic trouble codes (DTCS): P0AC0; P0A1F; P0A7F; P0AFA (hybrid battery pack/system). Improvements have been made to the HV ECU and battery ECU hardware to correct these conditions. *PE
Component: Engine and engine cooling:Exhaust system:emission control
Summary: Toyota: Engine control: Some customers may report a M.I.L. on condition that occurs after operating the vehicle for extended times in ready on mode with the transaxle in the park position. *PE
Component: Exterior lighting:Headlights:High/low beam dimmer switch
Summary: HID headlight system - diagnostic tips. *NJ updated 6/17/08. *NJ
Component: Other
Summary: Techstream ECU flash reprogramming procedure. *KB
Component: Electrical System: Instrument Panel
Summary: Master, hybrid, and M.I.L. "ON" DTC P0A94, Information code 588. *KB
Component: Engine and Engine Cooling:Engine
Summary: Malfunction indicator lamp on with DTC P0AA6 or P3009, Information codes 526 and 613. *KB
Component: Electrical System
Summary: Automatic headlight leveling system warning light on or flashing. *TT
Component: Air Bags
Summary: Special Service Campaign (SSC) - 60B (Safety Recall) (Supplemental Restraint System (SRS) Airbag Replacement). Due to improper assembly of the airbag inflator, which is incorporated into the SRS airbag assembly (side airbag, curtain side airbag or driver knee airbag), some inflators were produced with an insufficient amount of the heating agents necessary for proper airbag deployment. *TT
Component: Engine and Engine Cooling: Engine
Summary: M.I.L. on DTC P0300, P0301, P0302, P0303, or P0304. *TT
Component: Electrical System
Summary: Special Service Campaign (SSC) - 50P to reprogram the ECM system which may cause some or all of the warning lights to illuminate: master, hybrid system, engine, vehicle stability control, and brake. *TT
Component: Electrical System
Summary: Repair instructions and diagnostics for the SFI system. Repair manual correction. 00400-RM107-5U1. *TT
Component: Electrical System
Summary: Diagnostics for the hybrid control system. Repair manual correction. 00400-RM107-5U1. *TT
Component: Engine and Engine Cooling: Engine
Summary: Engine mechanical - Engine (1NZ-FXE). 00400-RM107-5U2. 00400-RM113-0U2. 00400-RM110-5U2. *TT
Component: Fuel System, Other
Summary: Fuel - Fuel system (1NZ-FXE). Repair manual correction. 00400-RM113-0U2. 00400-RM107-5U2. *TT
Component: Engine and Engine Cooling: Engine
Summary: Malfunction indicator lamp on with diagnostic trouble code P0A60, P0A63, P0A72, P0A78, or P0A7A. *TT
Component: Engine and Engine Cooling
Summary: MIL ON DTC P1121. *SC
Component: Engine and Engine Cooling: Engine
Summary: Malfunction indicator lamp on with diagnostic trouble code P1151. *TT
Component: Engine and Engine Cooling: Engine
Summary: Diagnostics - Hybrid control system. repair manual correction. 2005 Prius. 00400-RM113-0U1. 2004 Prius 00400-RM107-5U1. *TT
Component: Engine and Engine Cooling: Engine
Summary: International inverter coolant leak resulting in malfunction indicator lamp on with diagnostic trouble code P3009 and Information codes 526 and 614 (inverter/converter assembly). *TT
Component: Engine and Engine Cooling: Engine
Summary: Malfunction indicator lamp (MIL) on with diagnostic trouble code (DTC) P0AA6 OR P3009, information codes 526 & 614. *TT
Component: Equipment: Other: Owners/Service/Other Manual
Summary: Repair manual correction. *SC
Component: Electrical System
Summary: Repair manual correction for the engine control system - SFI system (1NZ-FXE). 00400-RM107-5U2. *TT
Component: Service Brakes, Hydraulic: Antilock: Control Unit/Module
Summary: Repair manual correction for the side control ECU assembly (brake). 00400-RM107-5U3. *TT
Component: Engine and Engine Cooling: Engine
Summary: Engine oil specifications. *TT
Component: Electrical System
Summary: Combination meter repair manual correction for the 2004 Toyota Prius. 00400-RM107-5U2. *TT
Component: Engine and Engine Cooling: Engine
Summary: Malfunction indicator lamp on with diagnostic trouble code P3191, P3190 and/or P0A0F. *TT This bulletin supercedes EG027-04 dated 07/14/04. *TT
Component: Engine and Engine Cooling: Engine
Summary: Malfunction indicator light and master warning light on condition that may occur after slowing down and stopping and when attempting to restart. *NM
Component: Engine and Engine Cooling: Engine
Summary: Malfunction indicator lamp on condition with diagnostic trouble code (DTC) P0136 and/or P0138. *TT *MJ This bulletin is replacing previous bulletin 01803R 12/02/2003. *NM
Component: Electrical System
Summary: Fuel gauge inaccuracy. *TT *TT
Component: Structure: Body: Door
Summary: Rear door frame blackout tape wrinkled. *TT
Component: Equipment: Electrical
Summary: Power window / roof initialization procedures. *TT
Component: Structure: Body
Summary: Limited Service Campaign (LSC) - 40E. To inspect and install an engine compartment seal on the underside of the hood to keep rain or carwash water from seeping into the engine compartment from the area at the top of the hood near the cowl. *TT
Component: Equipment: Electrical
Summary: Repair manual supplement: Smart key registration. *MJ
Component: Engine and Engine Cooling: Engine
Summary: Malfunction indicator lamp (MIL) on HV battery diagnostic trouble codes (DTCS) P3000, P3056 and/or other diagnostic trouble codes (DTCS). *MJ
Component: Equipment: Electrical
Summary: Hybrid vehicle on-board diagnostic. Special service campaign 40D. *TT
Component: Electrical System
Summary: Special service campaign 40D to reprogram the electronic control units (ECU). *TT
Component: Other
Summary: Emergency response guide location. *TT
Component: Electrical System: Wiring
Summary: Electrical wiring diagram repair manual correction. *TT
Component: Engine and Engine Cooling: Engine
Summary: HV ECU software update. *MR
Component: Electrical System
Summary: Special Service Campaign electronic control unit. *JB
Component: Power Train: Automatic Transmission
Summary: Introduction of new automatic transmission fluid. Toyota Landcruiser 2004 also included. Revised. *TT
Component: Other
Summary: 2004 My Prius pre-delivery service. *JB
Component: Electrical System: Battery
Summary: Maintenance for HV and auxiliary batteries at port and dealers. Revised. *TT
Component: Structure: Body
Summary: Pre-delivery service information for Prius. *MJ
Defect Investigations (1 record)
Date Investigation Opened: May 31, 2005
Date Investigation Closed: October 12, 2005
Summary: ODI opened PE05-029 based on 33 reports of alleged gasoline engine stalling on the subject vehicles. The subject vehicles are gasoline/ electric hybrid vehicles that can be operated in gasoline or electric modes, or a combination of both depending on the power demand. All reports allege that the gasoline engine shut down suddenly without warning. Some of the complainants reported that the vehicle continued to operate using the electric mode for a period of time after the gas engine stalled and some reported that the vehicle shut down at the same time that they felt the gas engine stalled. Some consumers reported that they were able to restart the vehicle either immediately or after allowing the vehicle sit for a short time, whereas others reported that they had their vehicle towed. During PE05-029, additional failure data was identified as noted in the failure report summary above. The complaint data represents incidents where engine stalling was alleged or where the vehicle was alleged to have one of the various conditions that causes the gas engine to stall. In its August 26, 2005 response to ODI's information request, Toyota identified various conditions that could cause the subject vehicles to experience a gas engine stall. If this happens, the driver is alerted by an audible sound and various warning lights. The vehicle will continue to operate in the electric mode and the electrically-powered brake and steering operation will continue to function normally. Analysis of the warranty data indicated that over 97% of vehicles experiencing a gas engine stall resulted from an issue with the program logic in the electronic control module (ECM) system, which may cause the ECM system to not start the gas engine when required. As a result, the vehicle will enter the limited operation mode described above. The majority of the ODI complaints also indicated that the driver experienced this condition in conjunction with the engine stall. During October 2005, Toyota informed ODI that it would initiate a special service campaign (SSC) to reprogram the ECM software on approximately 75,000 my 2004 and early 2005 subject vehicles to address the gas engine stalling condition. During this SSC, dealers will also apply special dielectric grease to a transaxle connector to prevent water intrusion which may also cause similar limited operation conditions. Based on ODI's analysis, this remedy should address most of the incidents resulting in a limited operation mode. Given these circumstances, further use of the agency resources in this matter does not appear to be warranted. Accordingly, this investigation is closed. The closing of this investigation does not constitute a finding by nhtsa that a safety-related defect does not exist. The agency will continue to monitor complaints and other information relating to the alleged defect in the subject vehicles and take further action in the future if warranted.
