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Brake Actuator Replacement Time: C1256 & C1391

Discussion in 'Gen 2 Prius Care, Maintenance and Troubleshooting' started by SRQ, Sep 4, 2018.

  1. SRQ

    SRQ Member

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    Looks like my brake actuator needs to be replaced. I looked at a bunch of guides on here on PriusChat, and it appears that this is a doable DIY project, although it will require quite a lot of time, patience, and bleeding the brakes once the procedure is finished.

    My question is this: what are my options? My car is salvage title so the warranty isn't applicable. I contacted my local dealership and am waiting to see what their labor quote would be if I installed a used part that I provide. It looks like the tools required are simple sockets/open end wrenches, and for some reason on one of the guides provided, clamps to what I assume is keep brake fluid from draining once this thing is removed.

    The plan is to replace the part, and have the car towed to a garage to have the brake fluid professionally flushed/bled. I could consider flushing the brakes myself, but I don't trust that kind of work to a first-time DIY.

    Anything I should be wary of regarding the used parts I want to buy? My main concern is possible contamination from whenever the part was removed/stored.

    Next question: isn't the actuator interchangeable between other Toyota vehicles? If possible, is it possible to purchase an actuator for a Toyota non-Prius at a possible better price and less mileage/wear?

    Lastly, I'd love to hear what other's experience has been replacing this part. I know there has been recent talk of a class action lawsuit, and I was wondering how to participate as well as document this repair for possible reimbursement down the road, because apparently this part should be outlasting the life of the car in the majority of cases, which appears to not be the case given the recent uptick in issues.
     
    Sezy likes this.
  2. Ryan Harrington

    Ryan Harrington Junior Member

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    I've done this repair on two different gen 2's at this point. I was very satisfied with the used part I got from carpartsource. I got the other from another site, and the part was not as clean or packaged as well. So far, neither have failed. I don't know whether or not you could substitute with a part from another non-prius vehicle. The bleeding done with techstream and the help of a friend was relatively painless, but took some time. The biggest part is just the labor involved.

    One thing I didn't realize the first time is that it involves a coolant change, so make sure you have your fluids before you start.
     
  3. SRQ

    SRQ Member

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    The guide that I looked at shows that you can just place the inverter to the side and still have enough clearance to replace the part. I'm planning to do that in order to avoid changing the coolant.

    Now I'm just waiting for the hybrid battery to start dying; thankfully as battery technology gets better and more hybrids/EV's are put on the road, by the time that happens it should also be a relatively affordable repair.
     
  4. Ryan Harrington

    Ryan Harrington Junior Member

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    I'll be truly impressed if you can just shove that inverter to the side and replace it without draining coolant. There is also a water pump in the way which is attached to the actuator assembly. But hey... if it works for you, go for it!
     
  5. SRQ

    SRQ Member

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    I was able to do it myself. If I had the option I'd have a friend with me to help carefully lug the inverter in a nice secure resting position with some padding to avoid scratching. I just made sure that the hoses experienced as little stress as possible and didn't rupture.
     
    Ryan Harrington likes this.
  6. John H

    John H Senior Member

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    After replacing the brake actuator, is the original unit rebuildable? I haven't been able to find any discussion of what is failing in the original actuator. seals ? o-rings ? check valves ? warped mating surfaces ? fractured or fatigued housing ?
     
  7. Skibob

    Skibob Senior Member

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    The only people that rebuild them is Dorman. I can’t think of anyone here who has done it.
     
  8. Travis Sanders

    Travis Sanders Junior Member

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    Bump. There has got to be a common failure inside. If we can nail down exactly what it is maybe we could fix all these old units very cheaply.