2004 Toyota Prius Recalls
The affected vehicles have a steering intermediate extension shaft manufactured with metal splines that may have an insufficient hardness. Over time, the splines may wear and eventually fail resulting in a loss of steering ability, increasing the risk of a vehicle crash. Toyota dealers will inspect the extension shaft and replace if necessary.
During manufacturing, a scratch may have occurred inside of the electrically driven water (coolant) pump at the coil wire, resulting in corrosion. The corroded wire may break and the water pump could stop. The corroded coil wire could cause a short circuit in the pump resulting in a blown fuse, creating a stall-like condition of the hybrid system while the vehicle is being driven. This may increase the risk of a vehicle crash. Dealers will replace the electric water pump to correct this concern.
Toyota is recalling 2004–2010 models for an accelerator pedal that can get stuck in the wide open position due to problems with the floor mat. This may cause high vehicle speeds that make it difficult to stop the vehicle, which can result in a crash. In order to correct the problem, dealers will replace the pedals, alter the shape of the floor, and/or replace the floor mats. Toyota will also modify software on certain models to ensure that the brake overrides the accelerator in the event that both are applied.
The intermediate steering shaft and slip yoke may crack when large forces are applied and the connection may separate. This could result in a loss of steering control. Dealers will replace the intermediate steering shaft and inspect and replace the sliding yoke if needed. The recall began June 9, 2006. The Toyota recall number is 60C.
On 133 vehicles, certain airbag inflators were assembled with an insufficient amount of the heating agents necessary for proper airbag deployment. In the event of a crash, if the airbag does not deploy as expected, the risk of injury will increase. Dealers will replace only the suspect airbags to correct this concern. The Toyota recall number is 60B. The Lexus recall number is 6LB.
CERTAIN PASSENGER VEHICLES MAY BE EQUIPPED WITH AN IMPROPERLY DESIGNED BRAKE LIGHT SWITCH. A SILICON OXIDE BUILD-UP OCCURS ON THE CONTACTS INSIDE THE BRAKE LIGHT SWITCH, WHICH CAN MAKE IT INOPERABLE.