Petition for an investigation into defect conditions in upper immediate steering extension shaft #2 manufacturing defect in the 2004-2009 Toyota Prius vehicles w/respect to recall 12V-537. An inspection revealed that the current loss of 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- assist 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. This allowed a metallurgical failure on the interior of the upper steering intermediate shaft, which consequently allowed separation of that shaft from the electrical steering power assist column. An examination of the shaft spline showed a long term deterioration of the upper intermediate shaft #2 inside spline as evidence by metallurgical shards of deteriorated spline metal still residing in the upper intermediate shaft cavity. Also, the cruise control would cancel and not re-engage, then there were times, where the cruise control would not dis-engage at all. The vehicle would drift off course whenever the consumer took his eyes off the road, for even a moment. The consumer would have to steer the vehicle constantly or it would drift into another lane. Apparently, it was due to a computer algorithm that would attempt to correct for wind and road surface anomalies.

- Reston, VA, USA

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 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

- West Lafayette , IN, USA

I was driving my 2005 Toyota Prius at 35mph (on cruise control). Traffic slowed, I tapped the brake to disengage cruise control, the car sped up, would not slow down despite my standing on the brake and I rear-ended the car in front of me. My passenger was badly injured, both cars were towed.

- Deerfield Beach, FL, USA

The critical safety concern is noted as follows: On October 21, 2005, I was traveling with the cruise control active at 55 miles per hour. Upon approaching a slower vehicle and checking traffic, I proceeded to accelerate the vehicle in an attempt to quickly pass the vehicle driving before me. Upon successful passage of the vehicle, I let off the accelerator and pressed the brakes several times, but the vehicle continued to accelerate under full power. Under the conditions, I tried to quickly disrupt this safety critical issue. To the best of my recollection I tried to slow the vehicle by pushing the power button, manipulating the cruise control lever, and putting the vehicle in neutral. All attempts were unsuccessful. Under considerable distress, traveling approximately 20 miles over the posted speed limit at this point, and continuing to accelerate, I elected to apply full braking force to the Prius while "laboring" the vehicle to a standstill on the gravel shoulder of the road. Regaining my composure, I pushed the power button, and the vehicle shutdown. The cabin of the motor vehicle exhibited a strong odor reminiscent of electrical motor smell. No root cause has been found to date. Vehicle was driven by dealer and issue was re-created during initial test-drive from porter.

- Battle Creek, MI, USA