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Classic Prius Repairs

Discussion in 'Generation 1 Prius Discussion' started by Patrick Wong, Apr 16, 2008.

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Classic Prius Owners only: Which failure has your car experienced?

  1. Transaxle

    7.6%
  2. Inverter

    6.8%
  3. Traction battery

    26.5%
  4. Engine ECU

    9.1%
  5. Hybrid vehicle ECU

    6.1%
  6. Electric steering gear

    21.2%
  7. MFD

    0.8%
  8. Front Struts &/or Rear Shocks

    13.6%
  9. Other Failure

    31.8%
  10. No Failures

    26.5%
Multiple votes are allowed.
  1. Patrick Wong

    Patrick Wong DIY Enthusiast

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    Location:
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    2007 Prius
    Model:
    N/A
    Classic Prius owners only:

    I'm interested in seeing how reliable your Classic (2001 - 2003 model years) has been. The poll will allow you to vote for multiple choices, so if you have had more than one listed failure, please vote for each one.

    If your Classic hasn't had any failures, please also vote. For purposes of this poll, let's not count an SSC (aka recall) as a failure. The traction battery reseal is an example of an SSC.

    I recently sold my 2001 at 75K miles. Here is my list of major repairs (all covered under warranty except the struts/shocks and the circuit opening relay):

    1/2001: Production date
    3/2001: Car first sold
    12/2003, 15K miles: power steering gear replaced
    9/2006, 59K miles: engine ECU (aka ECM) and circuit opening relay replaced due to DTC P3191 "engine does not start"
    11/2006, 61K miles: traction battery replaced due to DTC P3006 "battery SOC uneven"
    8/2007, 68K miles: replaced front struts/rear shocks
    2/2008, 75K miles: sold car

    Thanks!
  2. tochatihu

    tochatihu Senior Member

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    My 'other repair' was right rear wheel bearing (assembly), under warranty. The ECU and steering (listed) were under warranty.

    Routine maint - I bought engine oil, other fluids, filters, tires, wiper blades and 12 volt battery (twice, unfortunately). That was a 2001 up to 109k miles, last July.

    I don't know the current odometer on the vehicle, but it's probably running <10k miles /yr. If any problems develop, I'm sure to get an email asking for advice ;)

    Oh, the 90987-02006 headlight relay needed replacing $30, but I'd rather not say why.
  3. Patrick Wong

    Patrick Wong DIY Enthusiast

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    Hi Doug,

    Thanks for checking in...my guess is that you were flashing your lights too frequently at the young ladies passing by? ;)
  4. ea8631

    ea8631 Member

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    Location:
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    Your Vehicle Year:
    2001 Prius
    Currently have 171500 Miles (276000km).
    It currenly on its 3rd set of summer tire and 2nd set of winter tire.
    Other major parts had been replace are:
    • 12V battery,
    • traction battery (@151000mi / 243000km),
    • a inverter/converter unit (replaced with a used one since the new one is so expnsive),
    • engine ecu has been changed to an updated one (change it because the dealer think the engine ecu is dead, but the truth is the inverter unit dead.)
    • currently the steering rack act funny and it need to be replace (just receive the new rack, now just need to find time to put it on my prius).
    1 person likes this.
  5. mingoglia

    mingoglia Member

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    Your Vehicle Year:
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    Wait a minute, you've had a traction battery replaced out of your own pocket? I haven't actually heard of someone replacing this outside of warranty? What did it run ya?
  6. Patrick Wong

    Patrick Wong DIY Enthusiast

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    Thanks for your reply.

    With 38K PriusChat members, my hope is that we'll receive many more replies to the poll so that we can assess the relative reliability of the various Classic subsystems. Then, when a newbie is thinking about buying a Classic and asks how reliable it is, we'll have data to share, not just opinions. :ranger:
  7. hobbit

    hobbit Senior Member

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    Your Vehicle Year:
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    There was Jesse, who recently lost his Classic to some hothead
    kid who whipped a left in front of him... just shy of 350,000
    miles, original engine/transaxle/battery. He had been through
    a number of other parts over time, though, such as wheel
    bearings. I encouraged him to post a complete list but if
    you wander the thread there might be more details from him.
    .
    _H*
  8. ea8631

    ea8631 Member

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    Location:
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    Your Vehicle Year:
    2001 Prius



    Yeah, it happen in last year feb. The traction battery need to be replaced due to several cells have problem. Try to get Toyota Canada involved in this but they said my prius was way out of warrenties so they can't help me at all. The traction battery was replaced @151000mi / 243000km. I end up getting a huge discount on labour from my dealer but still the bill is almost CAD$4000 (just the battery it self is already CAD$3500!!! I don't know why that battery in Canada was that expensive because even a new one from US is CAD$ 1500 cheaper.). I was try to located a used battery at that time (that's what my dealer suggest me) but I just can't found one in Canada. There are several in US but all of them didn't willing to ship across the border (even the new one from US dealership). After consider the condition of my prius (it still look pretty new, the pics speak for itself), and the cost of the battery is actually cheaper than buying a new vehicle. So I just go ahead and order a new battery and put it on.

    [​IMG]
  9. mingoglia

    mingoglia Member

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    Wow, that's a big expense. Too bad you couldn't find it used. BTW, that's a nice looking vehicle you have there.
  10. ea8631

    ea8631 Member

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    Your Vehicle Year:
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    Thanks...there are other reason I that I rather not selling my prius because there aren't any new car that attract me (include the new prius), and it is hard to find a good condition classic prius with gps these days (I don't want to go thru the retrofit gps system again since the pics will speak for itself):
    [​IMG]
  11. Patrick Wong

    Patrick Wong DIY Enthusiast

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    OMG, that picture is amazing. Guess that just using an aftermarket GPS with suction cup mount would be too easy for you! ;)

    The other photo of your car's exterior is great. A beautiful car, I wish I still owned my silver 2001.

    Hmm, maybe there's a business in smuggling Prius traction batteries across the border into Canada. Anyway, glad that your car is running well again.
  12. ea8631

    ea8631 Member

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    ^ yeah...if only the aftermarket system can provide the maintance reminder and can still function even if I'm going thru a tunnel or some area didn't have sat reception. Even though it already 7 years old, I still love my prius.

    Yeah....not just the traction battery, even other parts as well. I just got a brand new steering rack from a US dealership for CAD $1100 shipped (the same part from a Canadia dealer they quote me for around CAD$4000!!!! That's CAD$2900 difference!!!!!!!!).
  13. kocho

    kocho Member

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    Patric - why not add to the poll the catalytic converter failure? It is a majorly expensive repair if done by the dealer, lead only by transaxle/traction battery replacements interms of cost ($2-$2.5K or so for the converter).

    I've had mine fail at 118K. My cost was $450 for a salvaged unit. And I read about such failures by other posters on the net...
  14. Patrick Wong

    Patrick Wong DIY Enthusiast

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    Hi Kocho,

    Thanks for checking in and voting.

    Yes, I forgot about the catalytic converter and you are right that this is a significant Classic failure item. However its too late for me to add items to the poll, so I hope that people will continue to reply with their comments regarding whatever "other" failures their cars had.
  15. bwilson4web

    bwilson4web 03 and 10 Prius

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    You might consider getting the Dept. of Energy fleet reports on Prius Classic and making 'faux' accounts using the VIN numbers to put in their data. If I remember correctly, one had a power steering failure. Then there is the Canadian taxi company.

    I put my data in but know directly of three failed batteries: (1) Huntsville last summer, (2) SC in Nov./Dec. and (3) FL in Nov./Dec. whom I continue to work with. The FL user is just replacing the failed modules.

    Then Florian has a friend in Germany who needed module(s) replaced in his pack.

    Bob Wilson
  16. tochatihu

    tochatihu Senior Member

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    Been waiting for that shoe to drop :D
  17. FL_Prius_Driver

    FL_Prius_Driver Senior Member

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    8729-Tires replaced due to very rapid edge wear (Recall).

    36268-Replaced Fuel Tank/Canister/Engine Computer(Huh?) under warranty due to Engine Check light/codes reporting Bladder Leak. P3191,P3101(id code 205)

    49286-Service Campaign for Battery Junction Sealing (Recall)

    56874-Rear Right Wheel Bearing replaced due to noise/failing ($356 non-warranty) Transaxle drain and fill (my request-$50)

    68129-Got Triangle of Death (first time) due to engine stalling while backing out of parking space. Drove to dealer and left overnight. Could not find problem, even with "TOD" still active. Reset and did not apply diagnostic $$ charge-Thanks.

    75071-12V Battery went bad ($290 non-warranty). Prius sites showing secret screen to monitor 12V battery is most welcome.

    82880-Car lost most power while driving down interstate. Went to dealer, got gas pedal/sensor replaced ($543 non-warranty)

    83411-TOD went on, but with no change in car behavior at all. Took to dealer and had HV battery replaced under warranty. P3000, P3006 - Uneven charge in HV battery.

    85546-Replace rear tires with Goodyear Regatta 2s due to cupping of left rear tire. ($186)
  18. tochatihu

    tochatihu Senior Member

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    FL, I suggest that you need a suspension alignment and maybe shims in the rear? You may have paid a bit much for the rear bearing assembly. On the other hand I have read up to $700 for the accelerator pedal assembly, so maybe it all balances out.

    Bob, you need to advertise your accel pedal rebuilding here - somebody in need may visit this thread.

    Patrick it would be most useful to somehow put the known transaxle failures into this framework, so we could begin to tentatively compare the various failure rates.

    If this project becomes very complete, it could be used to generate Prius cost per mile of 'extra repairs', along with statistics. That would be very interesting and superior to the anecdotal 'one-vehicle' numbers that I and a few others have posted.
  19. Patrick Wong

    Patrick Wong DIY Enthusiast

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    Hi Doug,

    Well, if I were to do that, it would artificially skew the %s in the poll results. Now that G1 has its own little sub-forum, I am hoping that more Classic owners will see and reply to the poll!
  20. Patrick Wong

    Patrick Wong DIY Enthusiast

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    Classic owners: a reminder, please respond to the poll if you haven't yet had an opportunity to do so.
    Thanks!
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