Summary
The Toyota Prius has 34 recalls spanning the 2001 through 2024 model years, with the most serious recent issue being a wiring harness defect on 2016-2018 models where the engine wire harness can chafe against the Power Control Unit cover, short-circuit, and start a fire.
Several other 2016-2018 concerns also carry serious consequences. On 2016 models, a capacitor inside the hybrid inverter can vibrate loose and shut down the hybrid system, causing a sudden loss of drive power. Also on 2016 models, a passenger airbag inflator defect can cause the bag to partially inflate without warning, startling the driver or striking a front passenger. The 2016-2017 parking brake cable can disengage from its mechanism, leaving the vehicle free to roll if it is not in Park. On 2022 models, a software error in the hybrid electronic control unit can shut the hybrid system down when the shifter is moved while driving, cutting power to the wheels. The most recent recall, covering 2023-2024 models including the Prius Prime, involves rear door switches that can allow water in, short-circuit, and let an unlocked rear door swing open while the vehicle is moving.
The 2010-2014 generation carries a cluster of inverter and hybrid drive issues. Transistors inside the Intelligent Power Module can be damaged by high operating temperatures, pushing the vehicle into a limited-power mode or shutting the hybrid system down entirely and stalling the vehicle. The 2010 model year also has a separate brake concern: nitrogen leaking from the brake booster pump assembly into the brake fluid reduces hydraulic pressure at the pedal, and an anti-lock brake software issue can cause inconsistent pedal feel and longer stopping distances on rough or slick roads. The 2012 model year Prius plug-in has a hybrid battery fuse that can fracture under sustained high-load driving such as a long uphill climb.
The 2004-2009 generation has two distinct steering defects. The steering intermediate shaft connects the steering wheel to the steering gear through metal splines that can wear over time and cause a complete loss of steering ability. Separately, the intermediate shaft sleeve can crack or separate under load, also resulting in loss of steering control. There is also a water pump recall on 2004-2009 vehicles where a corroded coil wire inside the pump can cause it to stop circulating coolant through the hybrid system. A 2004-only recall involves an accelerator pedal that can stick wide open due to an unsecured or incompatible floor mat. The 2004 brake light switch can accumulate silicon oxide on its contacts and fail to illuminate the brake lights.
The 2019 model has an instrument cluster short circuit that can blank the speedometer, odometer, and fuel gauge while driving. On 2001-2003 models, the steering linkage can loosen and reduce or eliminate power assist when turning left. The 2001 model year also has a steering pinion shaft that can become unstable if the steering wheel is repeatedly turned to full lock, and a torque sensor fault that causes the power steering warning light to appear and steering effort to increase unexpectedly. The original 2001 model has a crankshaft position sensor where engine oil can enter the wiring connector and deform it through heat expansion.
