2004 Toyota Prius recalls and problems

The 2004 Toyota Prius has 6 recalls and 610 owner complaints on file with NHTSA; the most reported problem area is exterior lighting.

How the 2004 compares

High

Fewest complaintsMost complaints

High complaint count among 27 Prius model years — 6th most.

6recalls

610complaints

38crashes

2fires

29injuries

72,436median miles

Owner complaints filed with NHTSA, not verified and not adjusted for sales. Ranking compares this model's own years only.

Does your car have an open recall?
Recalls apply to specific vehicles. Only a VIN lookup on NHTSA's official site shows whether yours is affected and still unrepaired.

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6 recalls

Steering

Nov 14, 2012 · NHTSA campaign 12V537000 · 669,705 vehicles

Problem: Toyota is recalling certain model year 2004-2009 Prius vehicles manufactured August 5, 2003, through March 30, 2009. The affected vehicles have a steering intermediate extension shaft assembly built with metal splines that complete the connection from the steering wheel to the steering gear. These splines may have been manufactured with an insufficient hardness.

Risk: Over time, the splines may wear and eventually fail resulting in a loss of steering ability, increasing the risk of a vehicle crash.

Remedy & notes

Toyota will notify owners, and dealers will inspect the extension shaft and replace it if it is one with insufficient hardness, free of charge. The recall began during December 2012. Owners may contact their Toyota dealer or the Toyota Customer Experience Center at 1-800-331-4331.

Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.safercar.gov.

Engine

Nov 14, 2012 · NHTSA campaign 12V536000 · 350,662 vehicles

Problem: Toyota is recalling certain model year 2004-2009 Prius vehicles manufactured August 6, 2003, through March 30, 2009 and FCHV-adv vehicles manufactured December 12, 2008, through September 13, 2011. During manufacturing, a scratch may have occurred inside of the electrically driven water pump at the coil wire. The coil wire may corrode at the scratched portion.

Risk: The corroded coil wire may break and the water pump could stop. The corroded coil wire could cause a short circuit between coil wires and a possible open 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.

Remedy & notes

Toyota will notify its owners, and dealers will replace the electric water pump, free of charge. The recall began on January 17, 2013. Owners may contact their Toyota dealer or the Toyota Customer Experience Center at 1-800-331-4331.

Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.safercar.gov.

Vehicle Speed Control

Oct 5, 2009 · NHTSA campaign 09V388000 · 4,445,056 vehicles

Problem: Toyota is recalling certain model year 2004-2010 passenger vehicles. The accelerator pedal can get stuck in the wide open position due to its being trapped by an unsecured or incompatible driver's floor mat.

Original NHTSA wording

TOYOTA IS RECALLING CERTAIN MODEL YEAR 2004-2010 PASSENGER VEHICLES. THE ACCELERATOR PEDAL CAN GET STUCK IN THE WIDE OPEN POSITION DUE TO ITS BEING TRAPPED BY AN UNSECURED OR INCOMPATIBLE DRIVER'S FLOOR MAT.

Risk: A stuck open accelerator pedal May result in very high vehicle speeds and make it difficult to stop the vehicle, which could cause a crash, serious injury or death.

Original NHTSA wording

A STUCK OPEN ACCELERATOR PEDAL MAY RESULT IN VERY HIGH VEHICLE SPEEDS AND MAKE IT DIFFICULT TO STOP THE VEHICLE, WHICH COULD CAUSE A CRASH, SERIOUS INJURY OR DEATH.

Remedy & notes

Toyota filed an amended defect report on November 25, 2009, stating that dealers will modify the accelerator pedal and, on certain vehicles, alter the shape of the floor surface under the pedal. These changes address the risk of pedal entrapment due to interference with the floor mat. Redesigned accelerator pedals will become available beginning in April 2010 and dealers will replace any modified pedal with the new pedal if desired. Also, dealers will replace any genuine Toyota or Lexus all-weather floor mats with redesigned all-weather mats, or repurchase the previous mats from owners who do not want the new ones. Additionally, software modifications will be installed on camry, avalon and Lexus es 350, is 350 and is 250 models that will ensure that the brake overrides the accelerator in the event both brake and accelerator pedals are applied. Toyota will begin mailing letters to owners on December 31, 2009. Owners May contact Toyota at 1-800-331-4331, Lexus at 1-800-255-3987.

Toyota recall no. 90L/90LG.owners May also contact the national highway traffic safety administration's vehicle safety hotline at 1-888-327-4236 (tty 1-800-424-9153), or go to <a href=http://www.safercar.gov>http://www.safercar.gov</a> .

Steering

May 31, 2006 · NHTSA campaign 06V188000 · 170,856 vehicles

Problem: The intermediate shaft and sliding yoke in the electric power steering system can crack when large forces are applied and the connection May separate or the sleeve May fracture.

Original NHTSA wording

THE INTERMEDIATE SHAFT AND SLIDING YOKE IN THE ELECTRIC POWER STEERING SYSTEM CAN CRACK WHEN LARGE FORCES ARE APPLIED AND THE CONNECTION MAY SEPARATE OR THE SLEEVE MAY FRACTURE.

Risk: This could result in a loss of steering control of the vehicle.

Original NHTSA wording

THIS COULD RESULT IN A LOSS OF STEERING CONTROL OF THE VEHICLE.

Remedy & notes

Toyota will replace the steering intermediate shaft and inspect the sliding yoke and replace it if necessary. The recall began on June 9, 2006. Owners May contact Toyota at 1-800-331-4331.

Toyota recall no. 60C.customers May also contact the national highway traffic safety administration's vehicle safety hotline at 1-888-327-4236 (tty 1-800-424-9153), or go to http://www.safercar.gov.

Air Bags

Apr 3, 2006 · NHTSA campaign 06V096000 · 133 vehicles

Problem: On certain vehicles, due to improper assembly of the air bag inflator, which is used in the side air bag, the curtain shield air bag, and the knee air bag assembly, some inflators were produced with an insufficient amount of the heating agents necessary for proper air bag deployment. In this condition, the expansion force of the gas May be insufficient to properly inflate the air bag when the SRS system is activated during a crash.

Original NHTSA wording

ON CERTAIN VEHICLES, DUE TO IMPROPER ASSEMBLY OF THE AIR BAG INFLATOR, WHICH IS USED IN THE SIDE AIR BAG, THE CURTAIN SHIELD AIR BAG, AND THE KNEE AIR BAG ASSEMBLY, SOME INFLATORS WERE PRODUCED WITH AN INSUFFICIENT AMOUNT OF THE HEATING AGENTS NECESSARY FOR PROPER AIR BAG DEPLOYMENT. IN THIS CONDITION, THE EXPANSION FORCE OF THE GAS MAY BE INSUFFICIENT TO PROPERLY INFLATE THE AIR BAG WHEN THE SRS SYSTEM IS ACTIVATED DURING A CRASH.

Risk: This May increase the risk of injury to the occupant in the involved seating position in the event of a crash.

Original NHTSA wording

THIS MAY INCREASE THE RISK OF INJURY TO THE OCCUPANT IN THE INVOLVED SEATING POSITION IN THE EVENT OF A CRASH.

Remedy & notes

Dealers will replace the specific SRS air bag. The recall began on April 6, 2006. Owners May contact Toyota at 1-888-270-9371, Scion at 1-866-548-1851, or Lexus at 1-800-255-3987.

Toyota recall no. 60B and Lexus recall no. 6LB.customers May contact the national highway traffic safety administration's vehicle safety hotline at 1-888-327-4236 (tty: 1-800-424-9153); or go to http://www.safercar.gov.

Exterior Lighting

Nov 22, 2004 · NHTSA campaign 04V558000 · 183,090 vehicles

Problem: 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.

Original NHTSA wording

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.

Risk: If the switch is inoperable, the brake lights will not illuminate and can increase the risk of a crash.

Original NHTSA wording

IF THE SWITCH IS INOPERABLE, THE BRAKE LIGHTS WILL NOT ILLUMINATE AND CAN INCREASE THE RISK OF A CRASH.

Remedy & notes

Dealers will replace the brake light switch. The recall began during December 2004. Owners should contact Toyota at 1-800-331-4331.

Toyota recall no. Ssc 40/Lexus recall no. Ssc 4LH.customers can also contact the national highway traffic safety administration's auto safety hotline at 1-888-DASH-2-DOT (1-888-327-4236).

Recall text as published by NHTSA and the manufacturer.

What owners complain about

Exterior Lighting184

Electrical System177

Engine98

Service Brakes73

Vehicle Speed Control52

Unknown or other14

Owner complaints filed with NHTSA; one complaint can name several areas. Not verified by NHTSA.

Complaints by year filed

NHTSA investigations

Pedestrian alert sounds

DP22005 · opened Jan 27, 2023 · closed Aug 7, 2023 · led to recall 22V063000

Summary

NHTSA received a petition on or about July 18, 2022, requesting that Federal Motor Vehicle Safety Standard (FMVSS) 141 be applied to all electric and hybrid vehicles operating in the United States. The petition can be reviewed at NHTSA.gov under ODI Number 11486072. FMVSS 141 establishes performance requirements for pedestrian alert sounds for motor vehicles. The standard applies to hybrid and electric vehicles that have a gross vehicle weight rating of 4,536 KG or less or are defined as low-speed vehicles. The standard became fully applicable to all such vehicles manufactured on or after March 1, 2021.On January 27, 2023, NHTSA opened Defect Petition (DP) 22-005 to evaluate the subject matter described in the petition. On June 24, 2023 and as supplemented on June 25, 2023, the petitioner notified NHTSA he was withdrawing his petition. The petitioner indicated that, based on his review of data, there is no justification for asserting potential benefits that could be derived from actions sought by my petition. Based on the petitioner's withdrawal, DP22-005 is closed. Closure of this DP does not represent a determination by NHTSA regarding the subject matter of the petition.

Intermediate Steering Shaft Separation

DP13001 · opened Feb 21, 2013 · closed Apr 8, 2020

Summary

The Office of Defects Investigation (ODI) received a January 2013 defect petition requesting that it open an investigation on Model Year (MY) 2004-2009 Toyota Prius vehicles to address a possible manufacturing safety defect related to the steering column intermediate shaft.During the defect petition evaluation, ODI: 1.Reviewed the petition and its enclosures; 2.Reviewed the subject steering system layout; 3.Examined the Petition Vehicle?s history, including its repair history; 4.Reviewed and followed-up potentially related consumer complaints; 5.Assessed Safety Recalls 06V-188 and 12V-537; and, 6.Requested and examined complaint, claim, field report, service history, and warranty information from Toyota.ODI's review revealed that the petition vehicle had been recalled (Recall 06V188) to remedy a defect in the system identified in the petition with the remedy taking place prior to the failure that prompted the petition. Circumstances point to incorrect reassembly of the petitioner's vehicle by those who performed the recall remedy.ODI examined the issues raised by this petition to identify any related safety defect trend in the general subject vehicle population.That review identified a low rate of related consumer complaints (twenty-five over a eight year period from a population of over 600,000 vehicles) and no pattern that would identify either a safety defect not already covered by the two existing steering safety recalls by Toyota or a systematic problem with either recal…

ENGINE STALLING

PE05029 · opened May 31, 2005 · closed Oct 12, 2005

Summary

ODI OPENED PE05-029 BASED ON 33 REPORTS OF ALLEGED GASOLINE ENGINE STALLING ON THE SUBJECT VEHICLES.THE SUBJECT VEHICLES ARE GASOLINE/ ELECTRIC HYBRID VEHICLES THAT CAN BE OPERATED IN GASOLINE OR ELECTRIC MODES, OR A COMBINATION OF BOTH DEPENDING ON THE POWER DEMAND.ALL REPORTS ALLEGE THAT THE GASOLINE ENGINE SHUT DOWN SUDDENLY WITHOUT WARNING.SOME OF THE COMPLAINANTS REPORTED THAT THE VEHICLE CONTINUED TO OPERATE USING THE ELECTRIC MODE FOR A PERIOD OF TIME AFTER THE GAS ENGINE STALLED AND SOME REPORTED THAT THE VEHICLE SHUT DOWN AT THE SAME TIME THAT THEY FELT THE GAS ENGINE STALLED.SOME CONSUMERS REPORTED THAT THEY WERE ABLE TO RESTART THE VEHICLE EITHER IMMEDIATELY OR AFTER ALLOWING THE VEHICLE SIT FOR A SHORT TIME, WHEREAS OTHERS REPORTED THAT THEY HAD THEIR VEHICLE TOWED.DURING PE05-029, ADDITIONAL FAILURE DATA WAS IDENTIFIED AS NOTED IN THE FAILURE REPORT SUMMARY ABOVE.THE COMPLAINT DATA REPRESENTS INCIDENTS WHERE ENGINE STALLING WAS ALLEGED OR WHERE THE VEHICLE WAS ALLEGED TO HAVE ONE OF THE VARIOUS CONDITIONS THAT CAUSES THE GAS ENGINE TO STALL.IN ITS AUGUST 26, 2005 RESPONSE TO ODI'S INFORMATION REQUEST, TOYOTA IDENTIFIED VARIOUS CONDITIONS THAT COULD CAUSE THE SUBJECT VEHICLES TO EXPERIENCE A GAS ENGINE STALL.IF THIS HAPPENS, THE DRIVER IS ALERTED BY AN AUDIBLE SOUND AND VARIOUS WARNING LIGHTS.THE VEHICLE WILL CONTINUE TO OPERATE IN THE ELECTRIC MODE AND THE ELECTRICALLY-POWERED BRAKE AND STEERING OPERATION WILL CONTINUE TO FUNCTION NORMALLY. ANALYSIS OF THE WARRAN…

2004 vs. other Toyota Prius years

Owner complaints by model year; the darker bar is the 2004. Click a bar to switch year.

Questions

Does the 2004 Toyota Prius have recalls?

Yes — NHTSA lists 6 recall campaigns covering the 2004 Toyota Prius, the latest from Nov 14, 2012 (steering). A recall applies to specific vehicles: enter your VIN at nhtsa.gov/recalls to see whether yours is affected and still open.

What are the most common problems with the 2004 Toyota Prius?

Owner complaints filed with NHTSA most often mention exterior lighting (184), electrical system (177), engine (98). Complaints are consumer reports and are not verified by NHTSA.