How To Replace A Prius Actuator Assembly

The replacement cost of an actuator assembly can be fairly high. This is a project that is best for someone with good mechanical knowledge and proper programming tools. In particular, a Toyota Techstream diagnostic tool is needed for bleeding the brakes. It can also be a lengthy job. Expect to allow your mechanic 5 to 7 hours to complete it. Luckily, you can save big by ordering parts online and taking your Prius to a local dealership or trusted mechanic for a professional install. 

Preparation

If you want this project to go smoothly, be sure the mechanic you use has all the necessary specialized tools and materials, which are:

• Toyota Techstream (a diagnostic tool) for bleeding the brakes
• Flare nut wrenches (for hydraulic lines)
• Box/open-end wrenches
• Torx T30 (for one bolt on the inverter cover)
• Trim panel removal tools
• Multimeter
• Flexible line for brake bleeding
• Flexible tubing to bleed the inverter loop
• Socket and ratchet to remove inverter drain
• Replacement brake fluid (at least 32oz)
• Inverter coolant
• Needle nose pliers and offset long nose pliers

You’ll also need to get an OEM replacement actuator assembly. It’s important to get the right part number for your Prius. To do this, look up your Prius in our catalog of genuine OEM actuator assemblies. Remember that only OEM Toyota actuator assemblies offer:

• Toyota's Genuine Parts Warranty For 12 Months/12,000 Miles
• Skid Reduction: Genuine Toyota ABS Actuators Halt Wheel Lock-Up
• Consistent Braking To Better Protect Passengers And Pedestrians
• Toyota Vehicle-Specific Design, Enabling Better Stopping Performance
• Improved Brake Pedal Responsiveness With Genuine Toyota ABS Actuators

Here’s a couple of direct links to our best selling Prius actuator assemblies:

• Part No. 44500-47141: For 2006-2009 Prii
• Part No. 47070-47060: For 2010-2015 Prii

Steps To Take

This is an overview of the process your mechanic or tech will take to replace the actuator. Being knowledgable of the basics of the job may help you when discussing the work with your Toyota technician. Here are the basic steps:

1. Disconnect the starter battery and both Hybrid Safety Disconnect Rear batteries.
2. Take the windshield wiper assembly and the cowling off. This will give you access to the ABS actuator assembly.
3. Drain the inverter coolant, then remove the inverter. Use a voltmeter to be sure there is no voltage at the inverter connections.
4. Remove the cabin heat auxiliary water pump from it's mount, but do not disconnect the hoses.
5. Remove the actuator mounting bolts.
6. Disconnect all the brake lines from the actuator assembly.
7. Remove the actuator assembly.
8. Install the new actuator assembly in the reverse order.
9. Reinstall and bleed the inverter.
10. Bleed the brakes with Techstream. (This process will take about an hour.)

Got any questions about this replacement process? Contact us!