Headlight level sensor corroded?

[Ct. Ken V]

Hi, all,

Interesting how the dealers try to rip us off. Go back & look at posts 7 & 8. jpenny in post #8 took his sensor off, dis-assembled it, cleaned it, re-assembled it, & re-installed it, all in less than an hour. While Murrysville's dealer's PROFESSIONAL mechanic needs 2.5 hours just to remove the sensor & install a brand new one (should take only 10 minutes). Of course they should check the calibration of the sensor & aiming motor system to be sure the lights are properly aimed [according to the technical service bulletin issued on this problem back when it first became an issue (back in 2006, I think)]. I would think the whole job would only take about 1/2 hour, even with the calibration. I don't remember how long it took them to do mine back in 2006 & 60,000 miles ago, but I was also getting an oil chg & tire rotation too. I think I was out of there in only an hour (or less).

Ken (in Bolton,Ct)

[kkayser]

Mine is corroded beyond repair. One of the prongs broke off in the connector. A new wiring harness costs over $750. (the only way to get a new connector). It seems that the connector can be dis-assembled. There is a white part that comes forward quite easily. The rear water plugs are easily removed, but I can't move the metal parts. Does anyone know how to dis-assemble the connector or otherwise get the broken prong out?

[jayman]

I'd scrounge scrap yards for a harness. If you're *very* careful you can splice in the replacement harness connector. You MUST use heatshrink to seal the splice, or corrosion will start in the wires themselves

[kkayser]

Originally Posted by jayman

I'd scrounge scrap yards for a harness. If you're *very* careful you can splice in the replacement harness connector. You MUST use heatshrink to seal the splice, or corrosion will start in the wires themselves

Scrap yard owners know the cost of new parts. No one is going to sell me a $700 dollar harness for less than $300. If I can find a damaged harness, then I might get the connector for $20 or so. If I do a splice, I will do it inside the car where it will stay dry. I am confident that the connector can be dis-assembled. I just have to find out how to do it.

[mglenn]

Originally Posted by Bill Merchant

Here's a PDF from another PC poster on repairing his 2004 headlight level sensor. I wish I could give him name credit, but I only have his PDF. (about 600Kb)

Thanks so much for the PDF. Turned out one spring was so corroded it disintegrated. Are these 'gold-plated' springs? Any suggestion of where to get one?

Mike

[CBarr31]

Is the TSB for this posted anywhere?

Chris

[Ct. Ken V]

Hi, Chris,

The TSB is EL004-06 from April 28th, 2006. There are references to it here & at PriusOnLine [where mrv posted a link for me back in August (around the 22nd) of 2006 in the thread entitled "Recall done" for my benefit]. The problem is that none of the links work any more, so unless you subscribe to one of the services that come up while doing the search or join the Prius Yahoo group (which I think is free), you can't see the specifics.

Ken (in Bolton,Ct)

[krousdb]

Originally Posted by Bill Merchant

Here's a PDF from another PC poster on repairing his 2004 headlight level sensor. I wish I could give him name credit, but I only have his PDF. (about 600Kb)

I made the same repair on my 04 about 2 years ago. Too bad I didn't have this pdf. Two of the three springs were bad in mine. I used a spring from a ball point pen and cut it in half. It worked perfectly. Two years later, I haven't seen the MIL once.

[CBarr31]

Originally Posted by Ct. Ken V

Hi, Chris,

The TSB is EL004-06 from April 28th, 2006. There are references to it here & at PriusOnLine [where mrv posted a link for me back in August (around the 22nd) of 2006 in the thread entitled "Recall done" for my benefit]. The problem is that none of the links work any more, so unless you subscribe to one of the services that come up while doing the search or join the Prius Yahoo group (which I think is free), you can't see the specifics.

Ken (in Bolton,Ct)

Ken,

Thanks for the update I appreciate it.

Chris

[jimdesimone]

have fixed the sensor,however has anyone had the spot miscolor on the MFD where the warning light showes up.it is a faded spot