2002 Prius needs new steering rack at 98K?

[ca02prius]

This is the second big repair (or third, depending on how you count them) in less than a year, so I'm having some major worries about the trustworthiness of my 2002 Prius. In December 2008, at 90K, I had to have the ECU AND gas tank replaced (diagnosed by dealer; 10K past warranty; $1600). Now, at 98K, I'm told the increasing squeaking/groaning noise made by my steering requires that I get the steering rack and pinion replaced (non-dealer diagnosis this time, as I didn't trust the dealer; $1300). I've had all regular service at the appropriate intervals without any problems at all prior to the 90K problems, and I don't seem to have any choice about the steering gear, but how can I be sure I'm getting a good diagnosis? Is this the beginning of the end? I was really hoping to drive this car for at least 10 years, preferably longer (200K). Am I being unreasonable? How long should this car last, and what are reasonable repairs as my car ages? If anyone knows of a good, honest mechanic in San Jose, CA, I'd sure like to know! Thanks.

[Patrick Wong]

I question the need to replace the fuel tank in 12/08 unless the tech had checked the fuel line pressure and found it to be below spec.

Regarding your steering gear, if the only problem is noise and you haven't had the steering wheel jerk around by itself, then I suggest deferring a replacement until you have driveability issues.

Once your Prius is out of warranty, there are several components whose failure will lead to a hefty four-digit repair: transaxle, traction battery, inverter, steering gear, catalytic converter with HCAC chamber, MFD. If you have to depend upon dealer service then you'll be out big bucks.

In the Bay Area, Luscious Garage in SF and Art's Automotive in Berkeley have strong Prius service reputations.

[tochatihu]

If the steering assist 'cuts out' you'll know it, both by feel and the warning on the little TV. But with noise as the only symptom there I suggest you simply have the steering mechanicals inspected by a (any) shop familiar with modern front wheel drive cars.

If the mechanicals look OK then you can drive w/o concern. At least until Act II.

[ca02prius]

So, both of you think I should wait until I experience steering problems before replacing the steering gear? Do you think I'll have enough warning to do something? The noise has been so annoying, and frankly, I'm embarrassed every time I turn; it's particularly bad when I turn right and can be heard outside the car (on both sides, says my brother-in-law). I am definitely ignorant when it comes to cars; I just take it in for the scheduled maintenance and expect that it will keep running for at least 10 years!

[Patrick Wong]

If the noise is sufficiently annoying so that you are willing to pay $1,300 to make it go away, then go ahead and have the steering gear replaced now.

Otherwise, if you can live with the noise, I recommend that you defer the repair until you have driveability issues, such as having the steering wheel twitch violently... The problem will get worse as time passes, so you'll have plenty of opportunity to take action.

[ca02prius]

Thanks for the advice. Regarding your previous response, since this is probably the beginning of many more problems, would it make sense for me to consider looking at a new car in the next year or two? This hasn't been my practice in the past, as I like to see how many miles I can get on a vehicle, but I'm also less inclined to live with ongoing car problems when I don't have to. I guess I should check into blue book value vs. repair costs...

[ca02prius]

Originally Posted by tochatihu

If the steering assist 'cuts out' you'll know it, both by feel and the warning on the little TV. But with noise as the only symptom there I suggest you simply have the steering mechanicals inspected by a (any) shop familiar with modern front wheel drive cars.

If the mechanicals look OK then you can drive w/o concern. At least until Act II.

Well, here's the rest of the story, which I guess I now consider a cautionary tale... I should have taken your advice and not had anything done. But, because the "hybrid certified" folks at the shop, which I can now reveal as Pep Boys, convinced me that I needed the steering rack and pinion replaced, and instead of doing the smart thing and getting a second opinion, I ordered the part and paid in advance, as required (two mistakes here!). Then, after they replaced the rack, I found that the steering was worse than before they replaced it! No more whining noise, but instead, terrible vibrations when turning at slow speeds. So, of course I took it back. They took it to the dealer for recalibration to be told that a new ECU was required with any new steering rack. No more Pep Boys for me!

But, now what do I do? I took it back to the dealer who told me the steering rack was 'after market' and they didn't have an ECU that matched. They recalibrated the existing ECU and said to see how it goes. It seemed to work at first, but this morning it was shaking again. Any advice? Is this when I give up on the car, or is it worth putting more money into it? If so, what are my options? Anyone know of a good Prius place in San Jose? (Berkeley is really too far, sorry...)

[tochatihu]

I am unaware of aftermarket versions of this assembly. Perhaps it was from salvage, or an attempt at a rebuild? As a guess, an ECU can only calm this down if it uses a really long time constant in determining the sensor signals. If the shakes return, I don't have any ideas, other than taking action against Manny, Moe and Jack. Very sorry.

[ca02prius]

Thanks. It seemed to run a little smoother today after two 22-mile commutes to and from work. I'll hope it continues to improve. Lesson learned. I probably owe it to others to at least report the incident to the BBB.

[firegirl]

Ok. Aloha. I now find myself at actII -now what? I see that I am not alone in being frustrated with my dealership. I took the car in three times and was told it was ok. diagnostic when I complained of rattling came up clean. Then I am told the whole rack and pinion needs to be replaced (2k for the part). have been driving it and is just getting tighter and tighter - is that what you meant about Act II? if so -is it replaceable?
thanks

Originally Posted by tochatihu

If the steering assist 'cuts out' you'll know it, both by feel and the warning on the little TV. But with noise as the only symptom there I suggest you simply have the steering mechanicals inspected by a (any) shop familiar with modern front wheel drive cars.

If the mechanicals look OK then you can drive w/o concern. At least until Act II.