NHTSA Complaint #10437229 — 2005 TOYOTA PRIUS

TL* THE CONTACT OWNS A 2005 TOYOTA PRIUS. THE CONTACT STATED THAT WHILE DRIVING APPROXIMATELY 70 MPH WITH THE CRUISE CONTROL ACTIVATED, HE APPLIED THE BRAKE PEDAL IN AN ATTEMPT TO DEACTIVATE THE CRUISE CONTROL. THE CRUISE CONTROL WOULD NOT DEACTIVATE AND THE CONTACT HAD TO MANUALLY DEACTIVATE THE CRUISE CONTROL SYSTEM. THE CONTACT ALSO STATED THAT HE HEARD A SNAPPING SOUND COMING FROM THE STEERING WHEEL WHILE ATTEMPTING TO PARK AT 5 MPH. THIS FAILURE OCCURRED THE DAY AFTER THE CRUISE CONTROL FAILURE. THE STEERING WHEEL THEN BECAME LOOSE AND THE CONTACT COMPLETELY UNABLE TO STEER THE VEHICLE. THE VEHICLE WAS NOT TAKEN TO THE DEALER FOR A DIAGNOSTIC TEST. THE VEHICLE WAS NOT REPAIRED. THE APPROXIMATE FAILURE MILEAGE WAS 27,773 UPDATED 12/12/11 *BF THE CONSUMER STATED THE SRS AND ALL THE STEERING WHEEL MOUNTED CONTROLS WERE DISABLED. UPDATED 05/31/12 THE CONSUMER CONTACTED AN AUTOMOTIVE SYSTEMS ANALYSIS COMPANY, WHO INSPECTED THE VEHICLE AND DETERMINED THE STEERING ISSUE WAS CAUSED BY A CATASTROPHIC FAILURE OF THE UPPER STEERING INTERMEDIATE SHAFT. THE UPPER STEERING INTERMEDIATE SHAFT WAS DECOUPLED FROM THE ELECTRIC POWER STEERING COLUMN OUTPUT SPLINE. A CAREFUL EXAMINATION OF THE DECOUPLED COMPONENTS REVEALED THAT FOR AN EXTENDED PERIOD OF TIME, THE UPPER STEERING INTERMEDIATE SHAFT HAD NOT BEEN PROPERLY INSTALLED ON THE SPLINE OUTPUT OF THE POWER ASSIST COLUMN, WHICH ALLOWED A METALLURGICAL FAILURE ON THE INTERIOR OF THE UPPER STEERING INTERMEDIATE SHAFT, WHICH CONSEQUENTLY ALLOWED SEPARATION OF THE SHAFT FROM THE ELECTRICAL STEERING POWER ASSIST COLUMN. UPDATED 05/13/13*DT*JB