2011 Toyota Prius

The Office of Defects Investigation (ODI) has received a petition dated September 19, 2023 from the owner of a 2012 Toyota Prius V requesting that ODI reevaluate its decision to deny DP19-004. In the letter, the petitioner reported experiencing an unexpected and complete loss of brake power while driving, accompanied by multiple dashboard warning lights. This petition is based on the petitioner's direct experience and assessment that ODI closed DP19-004 because its prompting petition was withdrawn by that petitioner. ODI will review the work conducted during DP19-004 and a review of any additional related complaints and crashes via a new defect petition The petition and related materials can be reviewed at NHTSA.gov under the following ODI number:11553736.

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.

On September 19, 2019, the Office of Defects Investigation (ODI) received a defect petition from Mr. Roger Hogan requesting that the Agency investigate and recall certain Toyota Prius, Prius PHV, Camry Hybrid and Avalon Hybrid vehicles for a brake actuator valve wear condition covered under Toyota Customer Support Programs ZJB and ZKK (subject CSP?s). In support of his request, the petitioner identified 117 NHTSA complaints allegedly related to the subject CSP condition, including 60 reporting crashes. On September 30, 2019, ODI opened Defect Petition DP19-004 to evaluate the petitioner?s request for an investigation. In August 2020, the petitioner notified the Agency that he was withdrawing his petition. Because the petitioner has withdrawn the petition, we are denying the petition as moot and no further analysis of this petition is necessary.NHTSA is authorized to issue an order requiring notification and remedy of a defect if the Agency?s investigation shows a defect in the design, construction, or performance of a motor vehicle that presents an unreasonable risk to safety. 49 U.S.C. ?? 30102(a)(9), 30118. Because the petitioner has with withdrawn the petition, the petition is denied as moot. This action does not constitute a finding by NHTSA that a safety-related defect does not exist. The Agency notes that it is not required to receive a defect petition prior to opening a defect investigation and will take further action if warranted by future circumstances.

Vehicle Information: 2011 Toyota Prius, 144,000 miles. Component: Hydraulic Service Brakes, Electronic Stability Control, Anti-lock Braking System. Description of Incident: While driving at normal speeds, the vehicle suddenly experienced a severe reduction in braking capability. The dashboard simultaneously illuminated the Brake Warning Light, ABS Light, and Slip/Traction Control Indicator Light. The brake pedal immediately became soft, spongy, and squishy, requiring significantly increased physical foot pressure and a vastly extended distance to bring the vehicle to a stop. Upon inspection, the brake fluid reservoir remains completely full, but the brake booster pump under the hood cycles and buzzes rapidly every 10 seconds while stationary. A diagnostic scan confirmed trouble code C1391 (Brake Actuator Internal Leak). This indicates a severe internal hydraulic pressure bleed inside the braking module. [SEE ATTACHED] This is a known, widespread manufacturing defect previously documented under Toyota Customer Support Program ZJB. The manufacturer has refused to remedy this life-threatening safety defect because a 10-year calendar threshold has passed, despite the vehicle being well under the 150,000-mile limit established by the manufacturer. The vehicle currently poses an immediate safety risk to occupants and the public.

NHTSA ID

11756097

Incident

Aug 7, 2026

Every time I'd press the brakes there'd be an audible "click" noise and then when taking my foot off the brake it'd sound like a manual tire pump being pressed... kind of like air filling / hydraulic sound. This worried me (I don't mess around with brakes). One other thing that would happen is if I pressed the brake hard enough, the automatic braking system would kick in. The Toyota dealership claimed they couldn't hear anything and there were no warning lights so I took it to a reputable local mechanic. They diagnosed it as a bad ABS Actuator / Brake Booster and said it's common with this year of Prius. They also said it was good I brought it in now because it was not severe enough to totally fail (which could have caused an accident) but there was evidence of degradation and they also said the issue was causing sufficient brake fluid to not get where it needs to be.

NHTSA ID

11752939

Incident

Jul 1, 2023

Vehicle Information: Year: 2011 Make: Toyota Model: Prius Mileage at Failure: 58,769 miles Date of First Use: February 20, 2012 Complaint Description: As I was driving on the freeway, my 2011 Toyota Prius brakelights all came on. I pulled off, had it towed to nearest mechanic, who diagnosed a failure involving the brake booster, brake actuator, and ABS system at only 58,769 miles. The vehicle was diagnosed with Diagnostic Trouble Code C1391 (Abnormal Leak of Accumulator Pressure). According to my mechanic, the condition is caused by an internal brake fluid leak within the brake booster assembly with master cylinder. The recommended repair includes replacement of both the brake booster assembly with master cylinder and the brake booster pump assembly. The estimated cost of repair is approximately $4,100. This concerns me because the brake system is a critical safety component, and I believe such a failure at fewer than 60,000 miles is highly unusual and may pose a safety risk to drivers and passengers. Toyota previously issued a Warranty Enhancement Program for this issue, but my vehicle was denied coverage because the program expired on August 31, 2021, and the secondary coverage expired on February 20, 2022, ten years after the vehicle's first use date. Toyota declined any out-of-warranty assistance despite the vehicle's exceptionally low mileage. I am submitting this complaint so that this incident is documented as a potential safety concern involving premature failure of the brake booster and ABS system components on the 2011 Toyota Prius.

NHTSA ID

11746722

Incident

Jan 15, 2026

Shortly after purchasing used last year I had my brake, traction control, ABS, & TPMS lights come on when stopping at a stop light all at once. I went and had it scanned and no codes showed up. I hear a buzzing from the brake actuator/ brake pump every 15 seconds. This all has been going on for almost a year now. Over the weekend a loud buzzing warning alarm came on that will not turn off. I had it checked out and was quoted around 3500 to repair.

NHTSA ID

11745016

Incident

Dec 31, 1969

The ABS actuator (brake booster) went out suddenly. It is 100% available for inspection. It is being towed to M&M Auto Repair in Gaston SC. I was not sure if the car was going to stop when I was trying to figure out what was wrong. The car was acting like it wasn't going to stop until a few seconds later. People online have had a similar problem as me with prius models around my year to 2015. And it was a problem confirmed by the dealership. The component has not been inspected. Only diagnostics were ran. The ABS system light came on. But it would disappear for a long time then come back. So I thought it was a computer error for the longest until it proved to not be one. Because the brakes were working just fine like normal. Other than that, the light itself was playing peekaboo with me, making me believe that it was a computer error since the brakes were working just fine. Then on monday, the car started beeping excessively and the brakes were not working suddenly after being fine over the weekend....with no issues.

NHTSA ID

11744577

Incident

Jun 15, 2026

There is a known problem with the brake booster and skid control that was a part of an customer support extended recall program. Our Prius has very low miles (less that 60,000) so the issue didn't trigger for us until recently. Unfortunately, we are out of the extended recall program of 10 years or 150,000. This doesn't seem fair since it is a known and documented issue from Toyota. Unless we fix the issue, we are at risk of losing braking control. All brake lights on the dash are on and it is currently in the shop.

NHTSA ID

11741498

Incident

May 29, 2026

2011 Prius. 80k miles. Brake booster buzz coming on every 15 seconds now. ABs, traction and brake lights on. I’ve heard of many Prius owners with the same issue. I also have another Prius with the same issue at 120k miles. Brake booster accumulator codes popping up with 80k miles. It is a safety concern as the abs brakes don’t work. Almost every Prius is effected by this.

NHTSA ID

11736723

Incident

May 9, 2026

I was driving my car and suddenly the traction , hand brake and ABS sign started showing up. I usually apply only 10% of force on brake pedal but after this I have to apply almost 60% of force to even slow down the car. Almost 90% force to stop the car It has threatened safety of my family. When diagnosed at autozone they told cannot determine error code. When reading in internet this seems to be common problem in prius. Please help is fixing the issue as it is not at my fault. This seems to be manufacturing defect.

NHTSA ID

11734183

Incident

Apr 25, 2026

OBSOLETE NOTICE February 13, 2026: This bulletin is now obsolete. Please see T-SB-0009-26.

This bulletin includes basic procedures for performing a rescue charge on Ni-MH high voltage (HV) batteries. This bulletin should be used in conjunction with the applicable model and model year Repair Manual while performing a rescue charge. The GRX-5100 should be used wherever the Repair Manual references the Toyota Hybrid System (THS) charger.

Some 2005 – 2026 Toyota vehicles that have undergone water intrusion may exhibit a condition in which a musty odor is present. Follow the procedures in this bulletin to remediate the odor and address this condition. The purpose of this Service Bulletin is to provide general guidelines and procedures for odor remediation. This Service Bulletin provides a guide on how to prepare and treat the interior of the vehicle for odor remediation. Refer to the applicable model and model year Repair Manual and the EPA (Environmental Protection Agency) website for the most up-to-date safety and precautionary guidelines.

Acid rain results from rainwater or other airborne moisture that become acidic due to industrial chemical impurities in the atmosphere. If these acidic compounds settle on an exposed vehicle, especially the horizontal areas such as the hood, roof, and decklid, significant damage to the painted surfaces can occur. Acid rain damage can typically be identified on vehicles by the presence of stains on the paint surface that resemble hard water spots. Unlike water spots however, acid rain damage cannot be removed by regular washing procedures. Also, because acid rain can etch and soften the paint, normal buffing or polishing repair procedures should not be attempted. This can cause further damage and result in visible depressions in the paint surface. The following are the three major categories of acid rain damage: •Minor damage: requires only buffing to repair. •Moderate damage: usually requires neutralizing, color sanding, and buffing. •Severe damage: extending beyond 1/2 mil of clearcoat on a pearl, metallic, or solid color, requires neutralization, sanding, and repainting. In cases where acid rain damage is minor, neutralization and buffing with a liquid-type paint finessing product may provide an adequate repair. Only specially formulated products outlined in this bulletin should be used for that purpose. Unfortunately, other than minor damage, there is no simple method of determining the actual extent (depth) of acid penetration other than color sanding a representative affected area until there is no visible etching or depressions, followed by measuring the amount of paint removed with either a magnetic or digital-type film thickness gauge. The procedures in this bulletin are intended for use by qualified body/paint technicians and should not be attempted by inexperienced personnel. It is the dealer’s responsibility to protect and maintain the quality of the vehicle’s paint finish after receipt at the dealership prior to the first sale. Perform frequent vehicle washing, as often as daily, during high heat and humidity periods to minimize the potential for paint damage due to acid rain exposure. This is especially important in geographical areas known for high frequency and concentration of acid rain and industrial fallout.

To prevent brake rotor rust from forming during transportation and storage, wheel film will be used instead of a cardboard type of anti-rust cover. The purpose of the wheel film is to shield the disc brake rotor from weather elements and initial rust before the vehicle is delivered to the customer. Consequently, the film should remain on the wheel for as long as possible.

The condition known as acid rain is caused by airborne chemicals or particles in the atmosphere, which mix with rainwater, nighttime dew, or high humidity to form acidic compounds. If these contaminants settle and remain on a painted vehicle surface, especially the horizonal areas of the hood, roof, and decklid, significant damage can occur. This damage is the result of actual etching of the paint and appears as pitting or water spots. As acid rain droplets on the vehicle surface evaporate, the concentration strength of the acid increases, causing deeper and more rapid damage. This evaporation and corrosive action also occur more rapidly on dark colored cars as direct sun heat increases. It is the dealer’s responsibility to protect and maintain the quality of the vehicle’s paint finish after receipt at the dealership prior to the first sale. In areas known for high frequency and/or concentration of acid rain, frequent vehicle washing during high heat or humidity periods will minimize the potential for paint damage caused by acid rain. It is further recommended that either reverse osmosis or deionized water be used to prevent water spotting.