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Second Prius with BENT Rear Beam

Discussion in 'Gen 3 Prius Main Forum' started by dorunron, Aug 26, 2016.

  1. dorunron

    dorunron Senior Member

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    I don't know what to say. I really think the durn thing was bent when I bought the car new, but cannot prove it.

    I recently replaced all four tires and paid for a alignment at Toyota. Bought tires from a tire shop.

    When Toyota brought the car back up after the alignment, they quoted a ridiculous amount to repair the car. Said the rear beam was out of spec and needed to be replaced.

    I have read about shims being used to fix this problem.

    FWIW, I think this is a bad design and really wonder if this is the main reason that they went to the wishbone suspension in the Gen IV.

    Has anyone successfully shimmed a Gen III Prius? If so, can anyone point me to a shop here in Texas that could do the work for me? Toyota already said "No, it can't be done". But I thought someone shimmed one here on PC...

    So everyone understands, the last Prius we had (Gen II) also had the same problem. I ignored it, but am frustrated since this car is so new. Plus Toyota (servicing dealer) is refusing to warrant it even though the vehicle is still under the 3/36 warranty.

    Thoughts anyone?
     
  2. DonDNH

    DonDNH Senior Member

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    I would suggest a call to Toyota corporate customer support. It would seem to me that other suspension components would be damaged if it was caused by abuse. Tires, wheels, shocks, bushings and the like.
     
  3. Mendel Leisk

    Mendel Leisk Senior Member

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    We got the rear beam replaced about 3 years back, maybe these parts prices can help. It was all brand new parts, salvage obviously cheaper. In Canadian dollars, but maybe closer to par then.

    image.jpeg
     
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  4. DonDNH

    DonDNH Senior Member

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    Was this done under warranty?
     
  5. Mendel Leisk

    Mendel Leisk Senior Member

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    Insurance claim after collision, $500 out of pocket. Total bill over $7000.
     
  6. dorunron

    dorunron Senior Member

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    Dealer did say the insurance might cover it. They were asking me if I hit anything or if the car has been hit. Still haven't contacted insurance yet. Thinking about calling Toyota Corporate.
     
  7. Kenny94945

    Kenny94945 Active Member

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    Second time...you've owned two different cars both with bent rear beams?
    Only you know for sure if impacts did this.
    Maybe the frame where the beam mounts is bent or rotted or oblonged.
    Maybe it is a failed bushing somewhere.
    Then how "they" know it is the beam and not a related part would be a lead.

    If repairing at a shop, at least in Calif, I believe there is some "law" about installing used suspension pieces.
    Whether this is considered suspension I am unsure.

    As for shimming...how is it bent?
    Twisted, bent in the center, one or both sides, etc?

    I guess the first step is to inspect the mounting bolt area and look for witness marks.
    At the same time look at all the rubber bushings.
    Maybe second, use a long straight edge across it.
    Might even be prudent to have the frame measured although that could be considered not inexpensive.
    Lastly I guess would be to remove the part to have full inspection access.
    The inspection or repair seems like it could take days if doing it yourself.

    Then as for shimming I'd guess the options would be on the mounting bolts or behind an a-arm mount.

    In for answers.
    I have no practical experience in this repair.
    Besides bent during manufacturing I can only guess as to the root failure cause.

    None the less, this repair seems costly and a pain in the neck IMO so an insurance claim with a $500 deductible could be the cheapest repair route.

    Good luck.
    Let us know.
     
  8. dorunron

    dorunron Senior Member

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    FWIW, I have put in a call to Toyota Corp about this matter. They have referred it back to Tejas Toyota, the servicing dealer to make a final determination. I am also investigating whether the new 2016 will exhibit this problem since the beam is no longer in the picture. The real problem is that the Toe adjustment is out of spec and can not be adjusted on the rear. This IMO is a BAD design and I believe this is one of the reasons why Toyota redesigned the rear end suspension with the new wishbone type suspension.

    I really like the Prius, but am getting ticked off due to this problem that is evident. Lot's of post's here on PC about the rear beam's being bent and shimming being done on Gen II's.
     
  9. bisco

    bisco cookie crumbler

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    how many miles on her, and what brought all this on?
     
  10. dorunron

    dorunron Senior Member

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    Just over 26K on the clock. I had a tire that could not be repaired. Started to buy two tires, but went with four and did an alignment like I always do when buying a set of tires. First alignment ever done on this car since I bought it new. Alignment on rear end is out of spec on toe. Can NOT be adjusted since the "beam" is bent.

    NOTE: Gen IV Prius DOES have an adjustment for the toe. I find that very interesting. To me it seems like Toyota saw the light with the beam and that is one of the reasons for the NEW design with the wishbone suspension.


    alignment.jpg
     
  11. bisco

    bisco cookie crumbler

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    a lot of people say the out of spec doesn't matter much. what is the condition of the tyres after 26k?
     
  12. dorunron

    dorunron Senior Member

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    They were wearing Ok from what I saw. Like I said, I only changed them because of the non repairable tire, plus the fact that the sidewalls were cracking. Starting to show their age... But to answer your question all of the tires were wearing properly. I rotate the tires religiously every 5K.
     
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  13. bisco

    bisco cookie crumbler

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    sounds like you're good, that seems to be the consensus.
     
  14. JC91006

    JC91006 Senior Member

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    Maybe they are all bent. I personally don't worry about it, tires are wearing evenly and it's the rear
     
  15. grnd0

    grnd0 Member

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    I purchased a 2010 about 6 months ago with only 52,000 miles. Around town it drove OK but on the highway you would fight to hold a straight line. Got an alignment and the right rear was toed out a little. You pay for a 4 wheel alignment yet they don't touch the rear. It's basically a very easy toe adjustment they do for $95. I went searching for a fix and found the shim kit. Looked pretty easy so I ordered it and a new hub. I had checked my wheel and tire temperature after a highway drive and found the right rear to be much hotter than the rest. Figured the bearing might be going bad. Think it took me about an hour and a half to do. Shim was around $15 and hub $65.
     
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  16. Mendel Leisk

    Mendel Leisk Senior Member

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    This is ours after the aforementioned rear beam replacement. Not sure but I think the rear left toe is 0.45? Tires seem fine.

    image.jpeg
     
  17. grnd0

    grnd0 Member

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    That rear toe is way out of spec.
     
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  18. dorunron

    dorunron Senior Member

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    I see that. I also note that the rear left toe on your's is also still out of spec, and that is after the beam replacement?

    Something still seems amiss to me.

    The more I learn about this, the more I think Toyota made a bunch of lemons and just won't admit it.
     
  19. Mendel Leisk

    Mendel Leisk Senior Member

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    Yes, alignment check with the new beam. FWIW, the tires look ok. My sense, just eyeballing both sides, is the rear camber is excessive on left side. Again, the tires seem ok, maybe that's the bottom line??
     
  20. dorunron

    dorunron Senior Member

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    Left Rear Camber on YOUR alignment looks good to me. Reading on your print out is -1.7 Acceptable Range IS -1.0 to -2.0 Not sure if you were talking about yours, or asking about mine. Mine is showing -1.4 which is also in spec.

    I really wonder if all of this is just BS from Toyota to make money, but I also wonder if they made a bunch of lemons and don't want to own up to it.

    As I have said, and I will repeat. This is the second Prius I have owned, and both of them have or had the bent rear beam plus quite a few posts about this problem here on PC and elsewhere.
     
    #20 dorunron, Aug 27, 2016
    Last edited: Aug 27, 2016
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