Radio Knob $4 fix

Discussion in 'Knowledge Base Articles Discussion' started by 2k1Toaster, Jul 11, 2010.

  1. 2k1Toaster

    2k1Toaster Brand New Prius Batteries

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    I'll try to get the pics back up. That server moved a long time ago and those temporary images were never moved over. I'll get them off the backup drive in a bit.
     
  2. 2k1Toaster

    2k1Toaster Brand New Prius Batteries

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    Images are back online, but the Priuschat software is being "smart" and not showing the link. Maybe it takes a cron job to scan for the real files and make the post viable again. I also can't edit the post to put the pictures back. Whatever...

    ============================================================

    Well when I bought the car in Feb, the radio's volume knob was missing.

    [​IMG]

    I looked online and found an OEM part website that sells the part for around $0.96USD. There were 4 parts that all looked the same with different product numbers. So for such a low price, I ordered one of each. When they arrived, they all looked the same.

    So for the fix you need:

    x1 #6-32 nut
    x2 #4-40 nut
    x1 #4-40 screw (flat bottom, about 3/4" long)
    x1 replacement knob
    and a bit of glue

    You can get the screws and washer from Home Depot in their $0.98USD/bag hanging hardware garden. The bags I showed came with nuts and screws. I bought them because I didnt know what diameter would fit the prius. The #4-40 fits inside the shaft and doesnt grip anything when in there. The #6-32 actually screws into the shaft. Would be perfect if there was a way to hold the shaft still while rotating in the screw. But there isnt, so we move on.

    [​IMG]

    Then assemble the nuts on the screw. So wedge the #6 screw between the 2 #4 screws. This is just to keep it in place. If you are good with glue then no need. But doing it this way, if you tighten it it keeps it perfectly perpendicular. It's hip to be square. :cool:

    When your little assembly is together, put the head of the screw into the knob hole so that the #6 nut is flush with the bottom of the replacement knob. It should fit snugly. Not tight, but not loose.

    [​IMG]


    Super glue, epoxy, bubblegum, whatever that sucker together. It doesn't take much. The force you apply will be rotational so try and get it all the way around. Also try to lock the nuts together. If you are working with something slow setting, getting it on the threads when you put the nuts on would be a good idea but totally overkill for a volume knob...

    Then put some more glue on the screw shaft (a liberal amount, thicker is better but doesnt have to be) and stick it into the broken radio knob hole on the poor Prius. Keep it still for a bit and make sure you only glue the screw to the inside part of the shaft of the donor hole. Otherwise it will not spin.


    [​IMG]

    [​IMG]


    So with a few US dollars worth of parts, and less than 5 minutes of time, my broken Prius radio knob is fixed and I defy anyone to spot it as a fake that didnt know. I see a lot of posts about the "$700 radio knob" because Toyota can't fix it, they just replace it. Well hopefully you mild DIYers can save a bunch of moola to get your car back to stock.:rockon:
     
  3. 2k1Toaster

    2k1Toaster Brand New Prius Batteries

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  4. Shaun_Collins

    Shaun_Collins Junior Member

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    Thank you the pics are a big help. Only question now is does the origional push to retrack button detent feature get negated / defeated by this fix as a compromise?

    Sent via my LG V20 on Tapatalk
     
  5. whitaksm

    whitaksm Junior Member

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    Someone borrowed my car and brought it back missing the turning knob ... we searched and found it in a door pocket, popped it in place as shown in the picture but now it doesn't pop out when pressed. I didn't know to look for a spring--is that all that I need to get it to work properly? If so, where can I get a spring?
    IMG_2730.JPG
     
  6. whitaksm

    whitaksm Junior Member

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    How about from Amazon?
     
  7. 2k1Toaster

    2k1Toaster Brand New Prius Batteries

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    Well mine has been working so far, and I don't want to temp the radio button gods to remove it and see if there is a spring there. The spring would either be on that shaft or internal to the thing that pushes down. I have used both types of rotary encoders before in my own projects. But you may try the standard spring from a ballpoint clicky pen. About the right size.
     
  8. hipchick

    hipchick Junior Member

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    Hi 2k1 Toaster,

    It's good to see this chat about the same issue I have, well I bought a used Prius and it already has the volume knob missing. Do you still have any spare parts? It looks like it is difficult to remove a part from an existing one that sells from a junk.. :(
     
  9. 2k1Toaster

    2k1Toaster Brand New Prius Batteries

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    Buy the new part from the Toyota parts counter. Will probably have to order it, but they're less than a dollar.
     
  10. vdub6127

    vdub6127 New Member

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    I had this issue too. I recently got a 3D printer and got into CAD. So I designed a replacement and printed it out. And it cost, well maybe a few cents? And I didn't have to wait for shipping or leave the house :)

    To my surprise, the replacement button fits great and works better than I thought it would. Although you do lose the ability to push the button in flush against the console (I never used this, and wasn't aware of it until after it broke off, so no harm here)

    It's up on thingiverse now, just search for "Prius Generation 2 Volume Knob" (this forum doesn't allow me to post the link)

    (the pix below show it in grey, but eventually I printed one in black to match better, as you should)

    Screen Shot 2018-10-09 at 12.08.57 AM.png
    Screen Shot 2018-10-09 at 12.08.46 AM.png
     
  11. fanplant

    fanplant Junior Member

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    Okay, I want to print a larger bigger tuning knob for my 2014 Prius Level 5 (not V) Nav, lane assist, etc. I can't get the existing knobs off to get an idea on what I need to print. I've searched here high and low and this thread is the closest I got. Thanks
     
  12. Joe Flies

    Joe Flies Junior Member

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    Sorry I may be a bit dense but I can't quite understand the instructions for assembly
    • The instructions say "So wedge the #6 screw between the 2 #4 screws." but the parts list doesn't list a #6 screw and lists 1 #4 screw (instead of 2) Is the parts list correct?
    • What is the #6-32 nut in the parts list used for? The instructions didn't mention where to put it.
    Maybe I can figure it out after I buy the items but just running it through my head and getting stuck
     
  13. ChapmanF

    ChapmanF Senior Member

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    I know it's been a few years, but I wondered whether you identified something in your design that could be changed to allow it to push in flush like the original.
     
  14. Joe Flies

    Joe Flies Junior Member

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    So I've given it a shot and here's my experience. I used 1 #6-32 x 3/4" flathead screw and 2 #6-32 nuts

    My volume knob broke off because my phone fell off the magnet and sheared the button while it was extended
    [​IMG]

    Step #1 was to remove the broken metal insert. I was able to do it with some needle nosed pliars and jiggled it out of the split. I'm sure there must be an easier way if it was possible to loosen the friction while pulling the metal piece out, but I managed to do it by wiggling it.
    [​IMG]


    [​IMG]

    The objective is to replace the broken metal piece with the screw, and use the two nuts to recreate the rimmed edge of the metal shaft. So the two nuts act as a centering mechanism

    [​IMG]
    To set the screw in the button, you have to glue it in. I didn't have much luck with my epoxy putty stick because it was kind of firm. I used epoxy resin instead under the screw. After it was set, I put a bit more resin from the top of the screw as well

    Then I took the final piece and screwed it back into the radio.

    Two side notes:
    • In my case, I'm fairly sure there's still a broken piece of the knob shaft in the radio, so the 3/4" screw is too long. It functions fine but sticks out further than it should. If I can get it out again, I will try dremelling it shorter.
    • I thought having the spring would help me restore the push functionality, but I lost the spring before I could get the right height worked out. It doesn't pop in/out the way it is now
     
  15. 2k1Toaster

    2k1Toaster Brand New Prius Batteries

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    Looks good! Unfortunate that they break sometimes but I am glad it is at least replaceable
     
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