Steering Pinion Shaft Problems of Toyota Prius

There is a clicking sound when you move the steering wheel back and forth when car is stationary, sound is coming from the steering shaft connection to the rack and pinion. Same clicking sound when car drives over bumps in the road. Previous recall of this problem for 2004 to 2009 Prius model stated a defective intermediate shaft. This problem sounds identical to the recalls of 2004-2009 Prius models.

See all problems of the 2010 Toyota Prius 🔎.

On 10-28-15, I was driving at a very low speed in a parking lot. As I attempted to turn left to park, I heard a loud crack sound in the steering wheel. The steering wheel became extremely loose and know longer could control the motion of the wheels. I could move forward and backwards but all steering control failed. Thank god I was in a parking lot! I immediately called Toyota and had the car towed there. They could not pinpoint the cause but said I needed a rack and pinion steering wheel shaft replacement, spiral cable, and steering shaft. Repair cost total is $2298. 77. My car is well maintained and has never been in an accident. I'm up to date on recalls so this was very upsetting to me.

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While my 16 year old son was practicing driving maneuverability with my wife in a parking lot, the steering shaft completely failed and the vehicle could not be controlled or steered. They parked the car safely and got a ride home. It was found that the splines on one of the intermediate steering shafts completely failed. The upper parts of the steering mechanism could turn without turning the lower parts. Toyota had a recall on some 2004-2006 vehicles with this exact description of parts but my VIN is not included in the recall. My failure is exactly as described: low speed with the steering turned at the end of travel. Searching the Prius forums on line, this is a common problem. Even cars that have had their steering mechanisms replaced have failed a second time. The issue is a defective design of the steering shaft. First, the electric power steering places forces on the steering shaft that would not exist in hydraulic power steering. The spline now has the force of the driver plus the boost of the power steering. At the end of travel, the power steering is forcing the linkage to turn even though the driver is just slightly turning the wheel. The rack and pinion and the associated shaft and link were designed for non boosted forces. The second design defect is the fact that this safety critical part doesn't include some type of redundancy for failed splines. In state of the art designs available since the 1970s, the clamping bolt provides a secondary fail- safe for loosing the spline interface. If the splines fail, the bolt interferes with the shaft after a few degrees of movement. This gives the driver a sloppy but safe way to drive the vehicle. Unlike the Prius failure, this system can keep the driver in control. My Toyota dealer did nothing for me because the vehicle is outside of the warranty. Toyota customer line did nothing.

See all problems of the 2006 Toyota Prius 🔎.

Two years ago, my car began exhibiting steering issues. When turning, both in reverse and drive, the steering wheel would shudder violently. After a few seconds, the shuddering subsided and the car steered normally. The issue was especially bad when the car was cold and improved as the car warmed up. Over the past couple of years, the issue has worsened, occurring with increasing frequency and with increasing violence. The steering wheel now jerks uncontrollably as I drive, and the steering wheel shudders when turning, sometimes so violently that I cannot hold onto the wheel or control the car. Turning left is becoming progressively difficult; the car pulls constantly and sharply to the right even though the tires on the car were just aligned. The 2003 Toyota Prius was already recalled for steering issues exactly as I describe. Toyota claimed the issue lay with the pinion shaft nuts. The pinion shaft nuts in my car were already replaced, per the recall. However, the steering problem persists and is growing worse. From my research, other 2003 Toyota Prius owners describe the same problem, and the same failure of the recall repair to remedy the problem. Mechanics not affiliated with Toyota have told me this is a common, well known issue with the 2003 Toyota Prius. According to the Toyota recall notice, "if the steering wheel is repeatedly and strongly turned to the full-lock position, there is a possibility the nuts securing the pinion shaft in the steering gear box assembly may become loose. . Read more...

See all problems of the 2003 Toyota Prius 🔎.