Replacing headlight bulb on Prius

I want to change out my 2001 Prius headlights for a more powerful bulb.

Will I have to take off the bumper as above or can I do this at home.?

What brand/make of bulb can I use to get mor elight on the road. I know
that lumens/candlepower is the better measure of the amount light that
get put out.

I have googled for bright bulbs and think that I want a PIAA HID for a replacement bulb.

Suggestions or answers ?

thanks

:confused:

I have a 2006 Prius. The driver side head light goes out now and then as I am driving. It is unpredictable. If I turn the lights off and then back on, the light works again.
The dealer said that it will cost about $450 to replace it. Does anyone have any idea what is wrong with it. It doesn't seem to be getting worse over time, and it does not go off too often.

I just replaced one at the dealership for $347, now the other is going. Yes, there is a pattern and someone is losing. Prius owners like you and I.

Please refer to http://www.wikihow.com/Replace-Headlight-Bulb-on-2005-Prius Those directions are for replacing the drivers side. My passenger side just blew out this week, I guess I'll be listing step by step directions for that.

We got all the way down to the spring clip and can't seem to get it off. Is it open at the top? what was the trick to getting it loose?

Oh yea 350 is ridiculous. Cost of any dealership work with Toyota and their refusal to certify or teach mechanics that aren't at dealerships is my biggest gripe with the Prius. since I drive my vehicals 2 - 3 hundred thousand miles being able to get my local mechanic to work on them is pretty important.

I, too, have a 2006 Prius. My version was package 7 (bluetooth, GPS, Leather the works) So, my head lamps are the most expensive - HID (high intensity discharge) I was quoted about $1000 for mine to be replaced. Obviously I will live with flipping my headlights off and on. However, I will add, I have been stopped over 7 times by the police and have gotten warings all but once. The last one was by the Mass State Police which I will fight as the only reason I was stopped was for "defective equipment" since my right light (passenger side) was out. The head lamp is not defective though as I can easily resolve by simply turning off then on the lights and they appear to work fine for a few minutes, at best. then they it will go out again. This problem is very consistent.

I too went to have my right side headlight bulb replaced today with one that I had purchased from an auto parts store. They looked up the make and model to get the part #. The cost of the bulb was $8.55. I then followed the diretions in the owners manual to replace the bulb but still couldn't reach it. I made an appointment to go to the dealer and was informed that it was not the correct bulb and I too needed an HID bulb which would cost me $300.00, which did not include labor and was told it is not covered under my extended warranty. They would not put the other bulb in the car for me and told me it is still working just at a different intensity and that the bulb may be on it way to burning out. It works intermiitently.

Same problem. You may add my name to your list. THanks

I have a 2006 Prius and am dealing with the second headlight right now. Drivers side went out this spring and was replaced under warranty. Passenger side is now intermittent. Same story with replacement from dealer, about $400. I am on the phone with Toyota USA right now registering my complaint, then its off to FTC website to log one there. I will post Toyota USA's response to the complaint here. As far as a recall, I don't think the car needs to be recalled just the headlights. Perhaps Toyota needs to extend the warranty for these HID headlamps to the life of the car. I will say that the service manager at my dealer was very sympathetic and relayed his own experience with his Prius and BMW needing these bulbs quite frequently. Of course this does not make up for Toyota's disregard of, in my opinion, defective parts.

Al, did you put in the cheaper bulb, and does it work? Kent

2006 Prius. Same issue. driver's side light works fine for awhile, flickers, then goes out. next morning seems OK.
I would be for some type of class-action...

Message to Barbara:

Which dealership did you go to that replaced your headlight bulb for you minus the $50 deductible? I am in the same position: 2006 prius, HID goes in and out at 46,000 miles. Dealership in San Francisco wants to charge $150 for diagnostic check, $250 for new bulb, and $45 labor. Ouch! I need to go to your dealer.

Thanks!

wait...
is this the same bulb, but on the opposite side?
these mechanics cannot be trusted.

do you really think toyota would build a car where you have to remove the bumper just to replace a light bulb?

I highly doubt it

change your mechanic

are you sure it was the bulb?
it sounds to me like it was more of an electrical connection problem or maybe a wiring problem.

then it would make sense to remove some of the body parts in order to fix it.

Prius headlights are HID lamps. Kind of like a florescent lamp on steriods.

HID lamps have both ballasts and starter circuts, like florescent lights. And when they go bad, they start to flicker and continiously restart.

DITTO! I have a 2006 Prius with 47000 miles, left light was replaced at no charge at 34000 miles by a dealer that I did not buy the car at in Pittsburgh, now the right light has been going out for the last 7 months. Of course everytime I take it to the Toyota dealership, it works. This headlamp issue began after owning the "new Prius" for 7 months. Finally today it was not working and i took it to the dealership. They want $492 to replace the bulb. I do have an extended warranty, but it does not cove "wear" items. I do not understand their explanation for the light going out and back on. They claim that the filament can refuse itself?????? I really like the car, but this headlamp issue is making me crazy. I am in Newnan, GA and the dealership is going to contact Toyota Monday morning to see if they will do anything about it. I do not have much confidence is a positive outcome. Add me to the list of unhappy Prius owners because of the headlamps.

Go to www.NHTSA.gov and go to "File a complaint about your vehicle or Child Seat". You will need your VIN number to file.

My Passanger side headlight went out off and on and would "re-set" when turning the light on and off. Both went off two weeks ago at night and reset with one on off cycle. Lukily I saw that it was out when my wife headed for work one morning so we swapped cars and I took it to tyhe dealership. They replaced the passngaer side and assured me that they would replace the driver side if I observed it going out again. Tonight first the driver side then then both went out as she was driving. The first trip they replaced the right front Headlight ECU 81107-47150 Computer sub assembly. One of the papers from the dealership has $278 handwritten on it. The one I signed and returned said $335.

I am going back in the morning and let them have another try.

This has got to be tough because the problem is only apparant when the dealership is closed - so figuring out what is really wrong will be tough.

I am convinced that Toyota wants this fixed - we just have to make sure we help them figure out what is going on...

My headlights keep going off and I keep having to turn my lights off and then back on again to get them to work. I had to do this 7 times this morning on my way to work -- I drive 70 miles to work and the 7 times happened the first 30 miles. Last weekend, I was at the dealership and had asked them to look at this because I thought it was happening. They found nothing.

Yesterday, I did some internet searching and found out that this is a computer problem and not a headlight problem, but the computer can damage the headlights, causing you to replace them.

I now have another appointment with the dealership tomorrow to look at this. It will be interesting when I hear what they say the problem is -- if they do indeed determine there is a problem. If it is not resolved, I will be filing a complaint. Eventually, they will get the message after we have spent $$.

My dealership actually told me that I had to replace BOTH lights if one goes out, for $990, as the lights come in pairs. My driver side headlight is out, the car has less than 30k mikes...In reading this blog, it is clear Toyota has an issue...I'll be contacting Toyota USA to file a complaint.

yup, that much.. mine for a 05 was $350 at the dealership.. and it is burning out when it starts goingoff by itself.. save you tax rebate for the other light bulB!

Have the same problem with my 2006 Prius. Took it the dealer and htey wanted $300.00 each to replace the headlights. The car had less than 37000 miles on it. Now my wife tells me the passanger light is going out again with 46000 miles in it. If I had known of this headlight issue and the cost for a headlightI would never have purchased the car. I have owned 6 different Toyota's in my life. All have been brand new. I still am driving a 1991 Celica with 210,000 miles on it. This headlight issue on the Prius is a terrible design or a very bad technical problem with Toyota designers. This light problem should be a recall issue by Toyota. If the problem is not resolved, as much as I like Toyota's, I will never buy another one. Add me to any list of unsatisfied Prius owners.

Have the same problem with my 2006 Prius. Took it the dealer and htey wanted $300.00 each to replace the headlights. The car had less than 37000 miles on it. Now my wife tells me the passanger light is going out again with 46000 miles in it. If I had known of this headlight issue and the cost for a headlightI would never have purchased the car. I have owned 6 different Toyota's in my life. All have been brand new. I still am driving a 1991 Celica with 210,000 miles on it. This headlight issue on the Prius is a terrible design or a very bad technical problem with Toyota designers. This light problem should be a recall issue by Toyota. If the problem is not resolved, as much as I like Toyota's, I will never buy another one. Add me to any list of unsatisfied Prius owners.

Although I must have missed the distinction in the initial discussion and comments, it appears that this is entirely about HID headlights that come with the Prius package #4, 5 and 6. I bought the package #3 2009 Prius, and it appears that it uses the commonly available headlamps, which can be replaced with blue or bright white higher intensity bulbs if desired by merely twisting them out as you do on most cars. I checked under the hood, the left side looks pretty easy to replace, the left side has little room, pretty darn tight, but I was able to feel around and reach it by hand, which is all that's needed pop it out. I might have to remove a panel or air vent to make it easier to get to if my paws are too large. What surprises me, is that for years, the entire headlight assembly could be removed from Camrys, Corollas, etc., by removing one fastener, and then use the heel of your hand to "whump" it in a forward motion, and the entire headlight assembly would pop out, almost seemed too easy. That's not an option on these HID headlights apparently. Darn if I'd pay the labor to replace these bulbs, I'd get familiar with a #2 phillips screwdriver and buy a $10 manual or find a web link that gives pretty good directions. For the guy that said we should have bought an American car, I would have, the Chevy EV1, but their primary interest was in building vehicles that could tow 10,000 lbs and all that stuff. After owning a Chevy Monza (read - Vega) and a Chevy Citation, both of which were a disaster, and after an Uncle of mine owned a Corvair years ago, it will take a LOT to get me back into an American owned car. If I had to change anything on the Prius, the AMERICAN Toyota organization, which calls some of the decisions on this car, need to put fully adjustable seats in these cars like everyone else is doing now, and let the seat go back another 2 inches, which shoudl be a cakewalk and cost virtually nothing more. Geeze, even my brother's Cobalt that costs $10k less, has seats that'll go back further and offers more leg room. Who is making these decisions at Toyota, a bunch of $!@%## midgets? Whoever it is, needs to be fired, there are as many complaints about front legroom in these cars from drivers over 6' tall, as there are about the HID lights.

same problem as the rest of you all. when i called the local dealer there was no mention of a possible issue across all cars with HID lights. i have an 05 package #7 with 23000 miles (not much driving in my opinion) and this is a real disappointment. toyota should step up to the plate if this is so common. i would have thought my platinum warranty would have helped but no go from the dealership here. any advice is appreciated

I filed a report with the NHTSA today on the HID light failure which I am now experiencing in my 2006 Toyota

Does anyone have more information about the replacement policy by Toyota for those of us affected by the apparent defective HID headlight bulbs on some of the Pruises?
I was just told by my caseworker at the National Toyota Consumer Office that Toyota would replace the cost of the bulb but not the labor. That policy does not seem satisfactory since I was also told that IF Toyota would offer reimbursement, then I would have to go through a Toyota Dealer for purchase and installation (which then commits me to their labor charges).

I have a 2007 Prius and just started to have the same issues with my passenger side headlight. I will first follow the suggestions and call Toyota Corp. and see what they will do for me. If I have to I will cause a big rukus outside the dealership and tell whoever I have to to get what I want and that is replacement of a defective product that I should not have to pay one dime out of my pocket. Wish me luck.

I have a 2006 Prius. The driver side head light goes out now and then as I am driving. It is unpredictable. If I turn the lights off and then back on, the light works again. It has been going on for 2 months. Now the other light is doing the same thing.
The dealer said that it will cost about $1726.00 to replace both H.I.D. headlights and 2 computers. I talked to Toyota customer relations (800-331-4331) today and the offered to pay for the parts about $1350 and asked me to pay the labor cost of $400. Plus they want me to pay for all of it up front and they will reimburse me after about 4 to 6 weeks. I DO NOT THINK I SHOULD PAY A DIME. THIS SOUNDS LIKE IT SHOULD BE A RECALL.

bryandrupp@gmail.com

My rt headlight has been giving me trouble (the intermittent blinking or just turning off) for several months.I have drug my feet a bit I suppose but in the mean time i have purchased a bulb from an internet advertiser. It was. of course, the wrong one and wouldn't fit I did learn how to change them. During the time i've been playing with it the left side bulb has given me trouble by going out twice. So far they always come back on when I turn the switch off and on. I can only imagine how conkfusiong it must look to the people coming the other way. Are the replacement bulbs at the dealer, or elsewhere faulty too? Is there an "elsewhere" at a reasonable price? I have news for the comment about having good milage and paying for it now. If I have had a great timein my Prius because my wife and I can drive and do the things that we used to do when gas was less. That freedom "pays for it now". I'll jump on the band wagon to encourage Toyota to step up. They've done well with Prius. They should be willing to deal with the part maker or help thier customers.

I also have a 2006 with the HID headlights. Before the warranty ran out the driver's side headlight would go off and on, and strangely when it did this the Bluetooth for the phone would stop working, and when the light came back on so would the phone. Of course they told me neither was connected and looked at me if I was stupid for even connecting them together, but of course they always went off together. Now the other headlight is going off and on and I'm out of the regular warranty but do have the extended, which doesn't mean much in this case.
They told me the bulb is going bad and would cost $400 and they just happened to have one in stock....lucky me! Installation would be another $85....at first I said yes, but then declined their wonderful $500 to replace a light bulb offer. I think the cost is higher because I live in Santa Monica and they can charge an arm and a leg. I've been reading all your posts (thank god for the internet) otherwise we'd all be in the dark (not a pun) about this obvious defect with these headlights. I figured I could buy the bulb much cheaper on the internet, and I've found various sites for these bulbs. But my intention is to harass Toyota until I get some kind of satisfaction about this issue. I've made note of all the numbers and websites you guys have included and will follow through on this whole thing and will post my results here. I think the tack to take on this whole issue is the one of safety.....we cannot be driving at night with lights going off and on at their whim. One is not terrible, but what happens if you are doing 70mph and the headlights fail you? A horrible thought and a major class action lawsuit would result from this, not to mention personal injury etc.
Let's all stay on this issue guys. In my experience if we're civil, persistent and won't take NO for an answer, we'll get some satisfaction. Every time you get somebody on the phone who says, "I don't have the power to do anything about this."
I respond without being rude, "Then why am I wasting my time talking with you, please let me speak with somebody who can actually do something for me."
This is so logical they usually get somebody.
Good luck, everybody.

go back to the top of this topic, and read my posting (3rd from top). Get a #2 phillips screwdriver and go for it.

I own a 2007 Prius and I am fumming! The dealership wants $356 for the bulb. I have no idea what they want for installation. They can pay me $28,000 for the car. I'm ready to trade my Prius in for an american car. Toyota should step up and fix the problem.

Have a 2006 with HID lights with same problem which started at 57k miles. Had had issues with my dealership in CT, have extended warantee, and dealership only seems to warm towards me when I mention contacting the attorney general office for consumer issues.

Let me know how you do.

Thanks

I had the exact same problem as everyone else and called the corporate office: 1-800-331-4331. Someone called my dealership the next day and arranged for the parts to be covered. I am going to pay for it and they are going to reimburse me. So basically, it should just be the cost of labor if you get in contact with the corporate office.

Everyone, please make sure you know what kind of headlight you have. The problem is with the High-Intensity lights, referred to as HID for the Prius. It is not included in all packages of the Prius. I have been told by several auto parts places that these particular lights can only be bought through the dealers and are not available anywhere else. They are still a relatively new product. It is the entire light that has to be replaced -- not just a bulb. So, please be careful about buying things over the internet.

Within a week of fixing my light, the other side started having problems, so I have had it fixed and am waiting for my reimbursement for both lights now.

I would also like to remind people about the low maintenance of the Prius. So far, I have had very little, minor things like oil changes and replacing a windshield wiper and air filter. On the whole, Priuses are very low maintenance. It is unfortunate we all did not realize this problem with the lights and how expensive they are to repair, but I am still a fan of the Prius.

Same problem with my 2005 Prius. Somewhat later then most of you poor people, at 55,000 miles. Right headlight out...went to dealer, they wanted $450 to replace a bulb that is NOT burned out, but goes on and off at will. After I picked myself up off the floor, I got real mad. Then I went on this web site, and found out what a real problem we all have. This is an eletrical issue and a saftey issue and Toyota needs to stand behind their cars. We all need to get very vocal and call Toyota and anyone else who will listen. I can't believe all the money spent replacing bulbs, when this isn't the problem. Someone is going to have to lose their life before anything gets done. What a crying shame. Please become proactive and get the word out there anyway you can. I am going to call Toyota, the newspapers, the dealerships, and anyone else that will listen. Sooner or later we will find an ear, that will listen. Toyota complaint # 800 331 4331

I have a 2004 Prius w/85K miles, out of warranty, and the right HID headlamp has been going off (and on) intermittently for almost 20K miles.

I called the Toyota corp # provided earlier (thanks!) and filed a complaint, and received a case number.

When asked what I wanted, I explained that replacing a headlamp for over $400 (parts + labor) was unacceptable, especially when the cause was not "normal wear and tear" but faulty parts.

A Sylvania HID bulb is about ~$110, and the process of replacing the bulbs (documented several places) takes about 20-30 minutes (for those comfortable working on cars). Even if I were a $300/hr lawyer, that would make the labor only ~$150 for a total of ~$260.

So, I would be satisfied with Toyota if they replaced the headlamps with quality replacements at no cost to me, and, also provided a list of acceptable replacement headlamp bulbs for those owners out of warranty (like myself) who are willing to do their own replacement.

I'm not going to hold my breath for this issue, but I can't expect things to change if I don't give feedback.

Well, add another to the list. My wife's 2007 Prius is having the same problem with the drivers' headlamp....On and off when ever it wants.....The car is also having problems with the drivers's rear tail light......I will be taking the car in soon for it is still covered under warranty.....I agree also, that this is a big safety issue that Toyota needs to adress....I will be calling Toyota also at the above number and filing a complaint....

All,
I just called the Toyota National Headquarters at 800-331-4331 and gave them a full report of my problem. The young lady was extremely professional and courteous, despite my anger. She said she is handing my issue over to a case worker who will contact me within the next 24 hours to talk about a remedy.
She actually encouraged me to share their number with any Prius owners who are having headlight issues so they can become aware just how pervasive the issue is. The number of reports they receive from owners directly influences how likely they are to see this as a big (recallable) issue. PLEASE call and give them your story and complaint.

There is really good information about this at PriusChat. This is a safety issue and you need to file complaints with the NTSB not the FHSA. The complaint form is online at http://www-odi.nhtsa.dot.gov/ivoq/. Contact your dealer's service manager. The manager in the service bay works on commission. If your dealer's service manager isn't able to do it comp, then call Toyota national.

I have a question after reading all (and I do mean, all) the posts here. Have we concluded that the problem lies in the computer or the HID bulbs, themselves? Obviously this is a recallable issue. I like the Partsquick solution for the parts, but the labor costs are absolutely exorbitant. I always avoid the dealer for parts or labor if I can. My problem is exactly the same as everyone else's, with a few variation. My '05 Prius, package 6 has 154k miles on it and the passenger side headlight thing started about 20k miles ago. It never flickers and the driver's side hasn't even thought about giving me a problem. The passenger side starts fine but in about 5 minutes of driving, it shuts off. Haven't tried the reset trick and am waiting for the "fix it" ticket from the CHP. Hmm. I just wonder if the HID bulbs from Partsquick is the direct replacement or generic. Thanks for all the comments and the consensus. All need to tell Toyota, not just a few. They will listen to our money, or lack of it, a lot better than to our voices, esp with the economy as messed up as it is. This is how we change things. Thanks again.

uh sorry that is not 14,000 it is 114,000 miles!

Although I had found information saying this was a computer problem, Toyota told me that it is a light problem. I believe they said it overheats. That is why it goes off again. I found that if it is off long enough, it will stay on once I flipped it back on -- but in most cases, keeping it off is not a possibility.

I am currious about the HID lights people have found on-line . Are you absolutely sure they are the correct lights for the year of the Priius you have? If not, Toyota may be able to nullify any warranted parts the lights may affect.

I did receive my check from Toyota, but it does take a little while.

I guess I'm one of the lucky ones. I have a 06 with 60,000+ miles on it. Just took it in for the major service and found out the right headlight went out. I too drive with my lights all the time. They told me it would cost $220 for one light to be replaced. I don't have HID but 60% of the cost was for labor. I balked at the price and I was able to get them to offer $140 for one side. I figured that if one is out then the other was going to go soon so I asked what would offer to do both...They came back with $250 for both light. I still think it's a rip off but I'm not going to crawl under and do it myself so I guess I'll have to pay it!! Try talking to the service people...they have the power to deal a little and if they don't then go to their manager. It can't hurt to ask!

2006 Prius- My good news is that my Prius does not have the HID headlights and the bulb was $40 and labor was only $25. The dealer said that Toyota was trying to make the cost of replacing bulbs easier on us.
My bad news is that because changing the bulb is so difficult the mechanic accidently gouged my bumper cover and now the dealer will have to repair or replace it. They felt badly and will take care of it.

I wonder if you guys can bailout on the HID headlight bulbs and go back to the conventional ones that mine uses. The dealer said they are trying to reduce even the HID bulds to $150.

Looks likethey may be getting the message...so there is hope.

Ok I know this is a Prius blog, but here is the thing...the headlight problem isn't just a Prius issue. I have an infiniti QX4, and my driver side HID headlight goes out randomly. From everything I have researched, this is an issue either dealing with the bulb, ballast, or cpu. Clearly, no one has an answer and the dealship sure as heck doesn't know. My question is, who has dealt with this and actually had a fix? What did you do? How much did it cost? What other things did you try before finding the fix?

My 2007 Prius just developed the headlight problem. I have a manual but was dismayed to see what it takes to simply change a light bulb. What a terrible design!

I'll probably try it myself if my local dealer won't do it under warranty. I don't trust the dealer (Rosner Toyota-Stafford, VA) where I bought it. They've already proven themselves untrustwory on a repair shop issue.

I'll go to the FTC site, but if anyone takes it to a class-action suit, please contact me.

Good luck, everyone.

Well I contacted Toyota about my headlight issues. (By the way, have you noticed how many Priuses are driving around with either a headlight out or a taillight out....scary) Got the thing reviewed by a manager, and after some days they declined mending the light. They told me this was based on my Toyota ownership history and dealer history.
I would not accept this decision and called back a week later voicing my displeasure. I have owned a Corolla and two Priuses, but they had no record of the other cars in their system....scary!
What it amounted to was Toyota saying I hadn't owned enough of their cars, and I hadn't used their dealer enough for servicing.
They did offer me a $250 voucher for any future service, BUT it could not be used for the headlamp problem.....very bizarre!
This was like not admitting to the headlight issues, which is very strange indeed because the first person I talked with admitted to the problem and said a team were working to resolve this issue.
I didn't decline the voucher or accept it, but I have since supplied them with the Vin numbers for the Toyota's I have owned.....we'll see what happens next.

Hi, I have a 2004 prius with exactly the same problem. I was going through Texas around July 2007 and the driver side headlights start giving me problems. The Toyota dealer told me that the all the wires and on that side need replacing and it will cost me more than $900. I did not want to spend that kind of money. A close friend had the same problem with a 2004 Toyota Sienna so I sort of guessed that this was an issue. Now my passenger side light has started to go off more frequently. I have taken the Prius to dealers here in South Florida but they couldn't find the problem. Their response was to replace both light bulb for a cost of each one of $400 plus labor, that service tech did not convince me at all because the parts department told me that when those light bulbs stop working they do not work anymore. and besides the service guy told me that it has something to do with filaments on the light bulbs itself. I am wondering if those HID lights in my car had those filaments that he is talking about. He did not give me any guarantee that the problem would go away anyway. I think that Toyota is one of the best companies in the world but I think that quality is going down now that they became the number one car selling company. Another friend of mine spent a lot of money to have the engine in his 2000 Solara replaced because it was giving him a lot of problems and soon after the 3.0 liter engines in these cars were recalled. They didn't even take care of his expenses even though it was just days before it was recalled. It's starting to look like they do not care about you. It seems that they are becoming like most companies that put out a product with known defects and just wait until there is a big enough noise to do something about it. I feel that if I am going to purchase a Toyota car that is so expensive that you should get your moneys worth and that you will trust that it last you more than that. After all we are buying not just a car but their word and trust in their word that it is a good product.
If in the end, though we only have one resolution,
let's sue those Mother F*&(&^&. Sorry for my french

2007 Prius. Passenger side headlight and taillight are not functioning. Rt. Turn Signal lilght works.
Add me to the list of disgruntled and unhappy owners.

OK. I'm going to weigh in on this problem.
I own a 2001 and a 2006 Prius. Headlights have never gone out on the 2001 after 150K miles.
Just a few hundred miles shy of the 36,000 mile warranty (just on the headlights), my left side headlight went out. When flipping the high beams on did not light the offending bulb (I did not at the time realize that HID headlamps do not have separate high and low beam filaments, but simply change the focus of the one HID capsule.), I immediately stopped into a parts store and bought a replacement bulb (non-HID). I did think it strange that the lights both went back on when I got back into the car, but I decided that I should replace it anyway. On the next day, I removed the offending bulb (not as difficult as some people seem to think) and discovered that it was some sort of rare-earth discharge lamp. Because this type of illumination system should be very reliable (there being no fragile filament to fatigue and break), I figured that I just had the bad fortune to run into a rare case of infant mortality, or just a defective bulb to begin with.
I took both new and replacement bulbs with me as I walked the mile to my Toyota dealer. The service person had no idea what I held in my hands. But the auto parts store across the street, where I had bought the incorrect bulb, took it back and warned me, "This could be expensive... more than one hundred dollars." He could not get me one... or even order me one, so he couldn't predict the exact price.
Fortunately, I got both lights replaced (the right side went shortly thereafter) under warranty. (Plus $80 labor)
Now, at 82K miles, here we go again. This time, I called Toyota (using the number mentioned above) and read them the riot act.
I first did some snooping on the Web, so I had some ammunition. I could get absolutely no commitment out of the representative, but he insisted that my local dealership must diagnose the problem before he could make a decision on a "possible reimbursement."
I had to make an appointment with my local dealer for them to have the car for a whole day. "What if the headlight does not go out?" I asked. "Are you going to drive it all day, using my gas and causing wear and tear?"
"Nope. We will not be doing that much driving."
So... Toyota will call the dealer and then me back on the day after the appointment with a determination as to what they will do (or not do).
************* Mounting Soapbox ************
I am a retired Electrical Engineer, and I am hopping mad. This is a safety issue, if I ever met one. We simply cannot be driving around at night flipping our lights off and on willy-nilly. It's got to be so annoying and distracting to other drivers, to say nothing about: What if we flip the lights off in order to relight one and neither comes back on? What then? Arrrrrgh!
A "super" lightbulb that costs THIRTY times as much as an ordinary one should last longer... a LOT LONGER... than the cheap one. The CFLs that we are all replacing our ordinary bulbs in our homes with are "guaranteed" to last as much as seven times longer than the incandescent bulbs that they replace. I should think that these HID capsules should outlast the car itself!
If any issue deserves a class action lawsuit, this one sure does. I might eventually get my headlights replaced for free, but what about those loyal customers who just take the "expert's" word as gospel, and shell out the better part of a thousand dollars to replace one lousy headlight?? They deserve their day in court.
************** Dismount Soapbox **************
Have a nice day!
Paul

Progress[?] report:
The "winking out" phenomenon is getting worse, so I was able to drive to the Toyota dealer with the headlight in its OFF state. They removed the bulb, cleaned up the contacts, replaced the bulb, and then could not repeat the failure. However, before I arrived at my home (2 miles away now, since they have moved to their new building), the light was out again, so I drove right back to the dealership for them to observe the pesky thing one more time. I have just called my case worker at Toyota, and he will consult with the service manager and call me back. Wish me luck, everyone. I want another free bulb!
Paul

Hello all,

I had the same problem that most of you are having. Contact Toyota, they seem like they are actually doing everything in their power to refund all out of pocket expenses. Per discussion with my case manager the are issusing me a check for the full amount and i should receive it within two week. I will post again if that doesn't take place. To get started call 1-800-331-4331 and get a case started, unfortunately you will have to front the money, after you get the bulb replaced either fax or mail a copy of the invoice to your case manager.

If you multiple Toyota dealership in your area i would recommend shopping around i got mine replaced for under $250 but received quotes for over $500 originally. Save yourself money up front and save toyota money in the end. I truly have to admit that i have been impressed by the way they are owning up to the problem. Probably why Toyota is number 1 overall. It hurts me to say this considering i have always been a Nissan fan.

Lastly it does sound like they will be covering this problem even if the car has over 36K miles.

I am having the sam problem with my 2007 Prius. took to Toyota today to be told after a three hour wait it could be the bulb for $191 or the chip $349 which was not covered by my extended warrenty. I love my car but hate the cost of repairs.

Same problem as posted above with my 2006 Prius. Just got the passenger side light replaced for $252.21 and two days later the drivers side light has the same problem. Thank God for this forum. I was feeling mighty peeved at this expense. Called the suggested Toyota number 800-331-4331 and they were very friendly and helpful. They knew about the problem, assigned me to a case worker and will coordinate with my dealer to get the problem resolved. Exactly what they will reimburse and what I have to pay for it still unknown but at least I won't be paying it all.

Thank you to everyone who posted before me. Certainly helped my day.

My Prius dealer told me bulb replacement would involve removing the bumper, for a whole lot of time and money.
My local mechanic, just squeezed his hand in there and did it, for very little time and money.

Guess which option I chose.

I changed my own bulbs in my 2006 Prius in 30 minutes for the paltry sum of 37.99 + tax (usd). Tight fit but I got them pulled out and replaced. I came here to complain about the size of the opening but never mind...Page 420 in your owner's manual...

I tried that number and it brought me to family life. Any other thoughts?

OK, I promised an update on my status, but have been remiss until now.
Toyota reluctantly agreed to replace my 2006 driver's side HID headlight, but said that this would be my last free trip to the well.
(Read my appends above.) I had to front the money first. They will reimburse me now that I have FAXed them the dealer receipt.
I am now in the process of waiting for my passenger side headlight to go. (My first pair of headlights went bad within a little more than two weeks of each other, both within the 36,000 mile warranty period. At that time, the bulbs would have cost $308 apiece and the labor was $80 to replace them. Today, the bulbs are nearly half the former price, but the labor cost remains about the same.)
I will try Toyota once more, but if they refuse to cough up any more dough, I will do it on my own nickel.
First, I will try to contact Aaron Reiff (see his append just above) to find out where to buy the new lamp. That price he mentions ($37.99 + tax) is the best I have heard about so far.

I would like to hear what information you have about this. The same thing is happening to my car! I've been quoted $250 by the dealer for it.

I removed the passenger side HID headlight myself (I do have somewhat smaller hands) after an hour and a half struggle brought it to our local repair shop and was told I probably wanted to check whether the warranty would cover it as the cost they gave me for the bulb was $275. I went to the dealership and indeed it was covered under the original 3 years and 36,000 mile warranty. Of course the driver side didn't go out now until I'm at 41,000 miles so now although it is less than 3 years I have no coverage. When I told the Toyota dealer repair manager that it made no sense to have a mileage restriction on this part given that there is no direct correlation to miles driven and light bulb lifespan he simply shrugged. I greatly appreciate this forum as I now have some potential resources to explore that may reduce the cost I was quoted of $455. Ridiculous! Remember that old slogan, I love what you do for me - Toyota! Like everyone else here, I wish Toyota would get in the driver's seat (pun intended) and accept responsibility to satisfy their customers. Becoming and staying the #1 car seller in the world is entirely driven (again) by customer loyalty which takes into account not only the purchase experience and the on the road experience, but perhaps most importantly the service experience. I will definitely be calling the 800-3331-4331 number listed previously and filing a complaint at http://www-odi.nhtsa.dot.gov/ivoq/.

Hi, Everyone!
I thought that you could all use a quick overview from an Electrical Engineer.
**************** mounting Soapbox, again ***************
HID = “High Intensity Discharge”. In order to light up one of these babies, you need to apply very high voltage to the lamp module (commonly called the “capsule”). The application of high voltage actually strikes up an “arc” (just like lightning) across the terminals inside the capsule. Once the arc is established, if measures are not instantly taken to limit the electrical current, the process will run away and the high current will destroy the capsule (and anything nearby). Current limiting is performed by a device called a “ballast”. So… in order to produce light, we require this thing that everyone has been calling a “computer” (a high-voltage power converter), the ballast (correctly named), and the “bulb” (more properly called the “HID capsule”).
What may be causing premature failure of the light (I may be wrong) is excessive depletion of metal on the contacts inside the capsule perhaps in combination with the release of contaminants trapped in the metal. I theorize that each startup of the headlights (in states with DRL requirements, every time the car is turned “on”) causes a few atoms of metal to be eroded from the electrode(s), and secondarily may release impurities trapped within the metal. Eventually, either the electrode(s) shrink to a size insufficient to sustain the arc, or the vaporized impurities interfere with the arc and cause it to be extinguished. This would explain the symptom that the light can usually be coaxed back on by cycling the headlight power switch. My headlights would never restart on their own, but if I interpret some of the previous appends correctly, some owners have seen theirs do so spontaneously. Perhaps the power converter is smart enough to automatically attempt to re-strike the arc.
It is obvious to me that the headlamp lighting system has one or more engineering insufficiencies. The system should be investigated, the failure mechanism uncovered, the guilty part(s) determined, and the system should be re-engineered to eliminate (or mitigate) the failure.
***************** dismounting soapbox ******************
Paul

I am with a law firm that is currently investigating complaints that the HID headlights malfunction in certain Prius model years. Check us out at http://www.girardgibbs.com/prius.asp, or give us a call toll-free at (866) 981-4800. You can also reach me by email at mcr@girardgibbs.com.

The filament is broken. Turning off/on welds it back together. It will not stay fixed.

My husband notice my 2007 Prius 45,345 miles, had a headlamp out last night. But this morning (foggy) strangely it was working again. This page was the first return on my metasearch. Thanks all, lots of good information. Sounds like I'll need it.

Sarah

Yes, Please help!! I am having the same issue. What do I ask for and how do I install? email: kamillawright@srctn.net

Powder_chowder:

If your Prius is "getting squirrely" on the highway, I would have the front end alignment checked.

My Prius hugs the road, straight and true. With the engine, electrical system and battery pack all located very low in the chassis, this car has an excellent center of gravity. And unless you are on snow/ice, this car should steer with no problems.

Unless your front end is out of alignment. And that can be a problem after you hit one-too-many potholes in the winter...

I had to replace both headlights after 54k miles last January for $750. Now 14 months later, my passenger headlight went out and dealer is wanting $$475 to replace 1? The manager is working on something to reduce to price but has not have an answer yet. Can't afford $500 for a headlight annually and reading all these comments, sure that the other one is going to go out soon.

The headlight problem on the Prius is not with the headlights themselves it is a faulty ECU board. HID headlights should last at least 3,000 hours or about 90,000 miles for the average driver. (www.jdpower.com) (mine is a 2006 with 85,000 and the bulbs are fine). The problem is that Toyota is banking on the fact that they can continue to fleece its customers by telling them that the bulbs dim, flicker, have filaments that burn out, and a bunch of other garbage. When an HID headlight burns out, it burns out, just like any other light bulb. It won't magically come back on (customer service said it was a safety issue to warn drivers that it needs to be replaced) SAFETY??? Driving down the road in the middle of the night and having your headlights fail completely is a "safety mechanism". BS!

The problem is a power interruption with the ECU board that powers the headlights. STOP replacing headlights and start filing complaints to the NHTSA, and Toyota customer service!

Another issue that I will warn you about is the ABS/Regnerative braking system. I had my brakes replaced by a non-toyota mechanic. (Sorry, It's routine maintence, and any mechanic should be able to replace brakes, change headlights, oil, etc.) When he finished bleeding the brakes the ABS remained on. He drove it and noticed the driver's side rear brake was sticking. Hooked it to the computer and nothing kicked out a code. He called Advanced Auto parts where we bought the brakes and they had a service warning that indeed it will not kick out a code and the rear brakes will stick. The fix was to take it to a "toyota certified mechanic". So, I called the dealership and was told, "yes, we need to reset the system for you (for $84 = ONE hour of labor!!) but in the mean time it's perfectly safe to drive you just don't have ABS." Well, I drove it the next day. I had a car pull out in front of me. I hit the brakes and did a 180 into oncoming traffic at 50 mph. Luckily I was not killed! I called Toyota customer service and informed them of the issue, and the fact that I had already reported it to the NHTSA, as well as being in the process of looking for a lawyer willing to file a class action lawsuit. Within 30 minutes I recieved a call back from customer service, they agreed that it was a safety issue and stated that they will be putting out a service warning. They also said, "ma'am, the dealership where your car is currently also noticed that your ECU board may be faulty when they were servicing your brakes. We are going to replace it for you free of charge." HHHMMM... magically they want to replace the other problem I've been fighting with them for 6 months now once I told them I filed a complaint. Seriously, this car is a death trap. The only way to force a recall is to report it to the NHTSA. Stop letting Toyota get away with this!

The NHTSA has started an investigation. The NHTSA Action # PE09019. They have requested a ton of information from Toyota which is due 7/24/09. There has been over 100 cases of both lights going off at the same time at speeds up to 70 MPH. Go to NHTSA to get the Defect Investigation; bring to dealership or mention when call Toyota. And MOST IMPORTANT, file a complaint with the NHTSA!

I have same problem with 2005 Prius with conventional bulbs...

5 min and 10 min solutions will be great! Any information will be very helpful to me.

Please help.

Sounds like the case referenced above "The NHTSA Action # PE09019" has been closed. http://www-odi.nhtsa.dot.gov/cars/problems/defect/results.cfm?action_num...
"THUS, A SAFETY DEFECT TREND HAS NOT BEEN IDENTIFIED AT THIS TIME AND FURTHER USE OF AGENCY RESOURCES DOES NOT APPEAR TO BE WARRANTED. ACCORDINGLY THIS INVESTIGATION IS CLOSED. THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT A SAFETY-RELATED DEFECT DOES NOT EXIST.

Does no exist my @ss.

My 2005 Prius with HID headlights has begun to behave as everyone here has so well described. I have been stopped only once so far (I guess I have been lucky). The problem is the passenger side headlight that randomly goes out and does come back after turning them off and on again.

Another problem I have had intermittently that may be related (??) is that my car alarm goes off in the middle of the night for no apparent reason (changing out the small battery in the front and emptying the overhead sunglass compartment did not solve the problem).

After reading the entries in this blog I am confused about some things:

1. Is NHTSA or Toyota planning to offer a solution to a serious this serious safety issue ?

2. If not, is there an active class action lawsuit in the works ? If so, can someone please post the contact info.

3. Does replacement of any of the parts (bulb, ballast, electronics, etc.) remedy the problem ? If so, can the replacement be done without resorting to a mechanic ? Are the parts readily available at Pep Boys, etc., or only Toyota ?

4. Does replacement with non-HID lightbulbs remedy the problem ? Is it safe to operate the car with an HID and non-HID headlight, or must they both be replaced ?

Thank you for the information.

Usually, it's not the lamp's fault. The lamp gets blown up by a bad power supply. HID lamps do NOT run on 12Vdc. Like florescent lamps they need a power supply transformer and ballast. Usually it's the power supply board that needs changing.

but Toyota dealers seem to be famous for replacing the lamp, but NOT the power supply. So a month later, your new $250 lamp burns out as well.

First, find out if you Prius has the standard lamps, or the HID lamps. Then find a REPUTABLE service shop to fix the problem RIGHT.

Why isn't there a recall on this issue? I have actually had both headlight go out at the same time....turn off and back on and they're fine. You never know when it might happen and they are so darn expensive it's ridiculous!

Same problem - 2006 Prius, Pkg 7. First time we had the problem was actually very shortly after purchase ... the dealer checked every connection and could not find anything ... they isolated the problem to a short in the bulb itself - their words, not mine. they paid for the replacement. passenger side developed same problem later ... we had to pay, but dealership comped us the labor. we called the regional guy for toyota and complained, as we have had several other electrical problems: window motor burned out, both tail lights have gone out, brake light ... seems to be generally a crappy electrical system ... toyota basically did nothing for us ... now driver's side bulb has developed prob again ... 3 bulbs in 3 years ... i have driven other cars more than 10 years and never replaced a single bulb! so now i want to change this bulb myself ... any advice on a source? i have xenon HID bulbs.

My headlights eventually both went black at the same time! I followed these steps I found from someone else, and it worked! Car was fixed free of charge:

If you are experiencing the Toyota Prius HID headlight defect failure you may be looking at a repair cost of up to $1,800. Here's a recommended approach for getting Toyota to take responsibility for the defect and to minimize your out-of-pocket expense:

1) Take your car to your dealer's service department and tell them that the HID headlight(s) are unexpectedly shutting off. Let the service writer know that you are aware that this is a common problem with HID equipped Prius (seems to be mostly 2005-2007). You should mention that the National Highway Transportation Safety Administration (NHTSA) has registered over 480 Prius HID headlight safety complaints. You can review the complaints by downloading the attached NHTSA database file or visiting the NHTSA database at: http://www-odi.nhtsa.dot.gov/complaints/index.cfm. You can also mention Toyota's Technical Service Bulletin: T-SB-0030-08 "HID Headlight System - Diagnostic Tips". If your car is still within the 3 year / 36K mile warranty period then Toyota should cover the repair cost 100%. If your service writer tells you that the repair is not covered (he may say that the bulbs are not covered under the warranty or point out that your car is beyond the 3 year / 36K mile warranty period) then ask if the service manager would contact Toyota corporate and seek Toyota's approval to cover the cost under Toyota's customer goodwill or loyalty program. If your dealer refuses to fix the HID defect free of charge then get a repair quote and move on to step 2.

2) Call the Toyota "Customer Experience Center" (This is Toyota's corporate customer service) at 1-800-331-4331. State that you have a safety defect with the headlights on your Prius. Say that you would like to report the problem to Toyota and open a case asking that Toyota repair the defect at no cost to you. The customer experience center representatives are extremely polite and will offer to open a case. They will supply you with a case number. They may take your information immediately or they may have someone call you back. You may want to call the 800 number and ask for Teresa at extension 73837. Teresa is very knowledgeable and helpful. She will know exactly what you are talking about when you mention the Prius headlight issue. You should be polite but firm. This is a serious safety problem and you know that it is a common problem on HID equipped Prius. They may start out by offering to cover 20% to 50% of the repair cost. Be firm and insist on 100% coverage.

3) File a formal safety complaint with the NHTSA.
Headlights that unexpectedly shut off while driving is clearly a safety issue. And it does appear that HID headlight equipped Prius indeed contain a design defect. Reporting a safety defect to the NHTSA is the first step in forcing Toyota to conduct a recall.

There are three ways to file a complaint:
Call the Vehicle Safety Hotline
Call 1-888-327-4236 or 1-800-424-9393 toll free (1-800-424-9153, for use by persons with hearing impairments)

File the complaint on-line
File the complaint on-line at the NHTSA vehicle safety Web site: www.safercar.gov. Select “File a Complaint” within the Defects and Recalls section of the home page.

U.S. Mail
Send a letter to:
U.S. Department of Transportation
National Highway Traffic Safety Administration
Office of Defects Investigation (NVS-210)
1200 New Jersey Avenue SE

I am reading this blog for the first time, having just lost my drivers' side light -- or had it just go flaky. It worked at the dealer -- you get the drift.

I am going to contract GM and FORD. They have and are developing new hybrids. They just might be interested in debunking the Toyota quality myth -- and the serious lack of ethics. Please add my name to any list.

First off, thank you all for your info... I was driving home last night when I noticed my passenger side light out. This morning it was fine. I called the dealer where I bought it and they said it was a bad light bulb - $150 labor + $150 for the part. Funny enough, when I talked to Parts, they said it sure didn't sound like a light bulb problem - exactly. So I called another dealer (Thompson in Doylestown, PA) and the service guy John (x2103) knew all about it - he said it's a bad computer blowing the bulb. So the solution is to replace the computer and the bulb. I have 51,500 miles on my 2007 Prius Touring Model (HID lights), but I have the extended platinum warranty (bought it for $900 from Toyota of Greenfield, MA) so they will cover the computer and all the labor, but I have to pay the $150 for the bulb. I called Toyota HQ and a case manager is calling me back tomorrow. Fortunately all I have to do now is ask for them to pay for the bulb ($150) since that is not technically covered under warranty. But given that the dealer is saying that the computer caused the bulb problem, this shouldn't be too hard to get accomplished. btw, I was told that Toyota has recently lowered the price of the bulb (to $150) so even though they still aren't allowing dealers to treat this for what it is (a defect) they clearly understand it should be. This is a pretty half-ass attempt to make it right. btw, my mother bought a Prius in 2001 and is now on her third one. I bought my first one in 2007 after owning two Corollas as a kid (my Porsche sits in my garage - that's how much I love my Prius), and I just convinced my brother to get the new 3rd generation Prius (under the Clunkers program). Toyota shouldn't be pissing off loyal customers... they need to take some responsibility here.

Everything that has been posted to this blog lately has already been covered (a number of times) in previous appends. Look back a week to Cindy L.'s post. She sums up what to do pretty well. Be sure to exhaust every avenue before ponying up your hard-earned dough. I am about to turn over 100 thousand miles on my 2006, and I have already gotten three free replacements from Toyota, so I just bought a pair of HID capsules for about $100.00 on the Internet.
(check out http://www.carhidkits.com/toyota-97/prius-hid-kit-352/)

I will have to replace my passenger-side headlight very shortly, since it has started to wink out with increasing regularity. Both lamps can be swapped out without having to remove the bumper! I will probably replace both sides, so that oncoming drivers will be symmetrically blinded by two new 6000K bulbs.

My 2007 just needed the second headlight replaced. The first one went at 37,000 miles, just out of warranty (the dealer did let me slide for the labor) and this week the second one went at 78,000 miles. I have been driving my own cars for at least 40 years and have replaced only one other headlight in these cars. There is definitely something wrong with these lights. Why won't Toyota pony up and admit it and repair them? In these tough times Toyota should accomodate its customers or they'll be someone else's customers. A letter is going to Toyota today; hopefully I'll get a satisfactory solution to this problem.

I just replaced the second headlight on my 2007 Prius. Love the car, just don't like the headlights failing. I have owned cars for 40+ years and have replaced only one other light. Toyota definitely has a problem as evidenced by the above comments. If they want me to continue as a customer (this was my 3rd Prius) they should stand behind their product.

I too have a problem with the headlight HID. I have a 2006 Prius with only 18,100 miles and the driver side light went out. I messed around with it and it went back on, but while driving it went out again.
This is just wrong of Toyota!
There is a class action against them. Please see the link.
http://www.girardgibbs.com/Prius.asp?_kk=prius%20headlight%20hid&_kt=c46...

Now do I pay for a new one?
Thanks for listening.
Joel

That's an ignorant comment. The Prius is made in America!

Just Called Toyota as well. They also said someone will call me back tomorrow. This is pretty freaking ridiculous. The guy on the phone seemed nice so hopefully something will come out of it. Hopefully.......something......

i have a 2006 prius,22,000 miles.so far no headlight problems,crossing my fingers.

I have a 2007 Prius w/ 52k miles on it. 3 months ago the passenger head lamp went out. We didn't really care due to the driver side was still on. Plus the passenger comes back on when restarted. Called Toyota in Wdbg, VA for replacement bulbs. $170+tax(each). quoted around $600+ to replace bulb in shop.. Driver side started going out but turning lights off then back on worked. I called local auto stores for HID bulbs. Bought pair at Amazon. Halo D4R 10000k for $95.00. Followed instruction from gschaut (2nd posting). It took a little longer than ½ hour but great instructions. I used 10mm socket instead of the Philips for underneath screws. New lights don’t work the greatest though. Have to turn off then on a few times before they stay on. Any ideas, suggestions?
Ballast bad? Computer controls need to be reset (if any)? Bad replacement bulbs?

Oh, and sorry about the 1/2 hr time estimate. I'm an engineer, and I keep forgetting that not everyone owns right power screwdrivers.

If you have to pull all those screws out with a hand screwdriver, it definitely takes longer.

They want $600 to fix the problem... a new bulb. I said no way -- they had better figure out a way to make this go away. We'll see what they say.

Most of the comments are from a year ago. Has anything new happened with the NHTSA or from Toyota. Mine is a 2008 and 45,000 miles later, the same thing happened to me. Passenger headlight out. Went to dealer, told $300 to change. Obviously not much has happened with this issue since 2006! I wish I had known, I would never have bought this car. Wait till the battery goes out! God knows how much that will cost. Becasue of their lack of concern, I will NEVER buy another Toyota product. And the NHTSA is obviously in cahoots with Toyota because there is no way that The NHTSA cannot find this a terrible safety issue. Hmmmm...How much do you think it cost Toyota to keep the NHTSA quiet???? Ojur tax dollars in action....

Hi Jeffrey,

I have a 06 Prius and just found out that the driver side lo beam is out. Read a letter from a guy saying that you had to take the inside fender and bumper cover off. Is that so? I can see the light connector but it's blocked by a black box of some sort.

Any suggestions?

Richard Brewster

There is at least one class Action Lawsuit in the works. Go here to help it go further http://www.wcclaw.com/CM/ClassActions/Toyota-HID-Headlights-Investigatio...

We are having the same problem. In the last two years we have to replace 4 bulbs. We realize that this is one year from when you made this comment; have you had any success in getting a recall or dealer compensation or anything?

Karin

My Prius is a 2004 and Toyota refuses to admit this is a problem. I feel GREAT frustration and don't really know what to do. It DOES seem like the NHTSA and Toyota have made this problem go away. I hate the fact that someone will have to die (like the floor mat issue) until someone really looks at the prpblem.

I am befuddled.

I have a 2007 Prius. At about 45,000 miles the headlights started flickering but would stay on most of the time. The dealer said it was the lightbulb and would cost $350 just for the bulb! Scoundrels!

I was driving on the highway at night at 65mph with traffic and both bulbs went out at the same time! I could have been killed! How dare they let such a defective product and safety issue go unresolved!

Sign me up for the class action lawsuit!

I have two 2006 Prius's. One has the HID headlights and the other does not. I have around 40,000 on each vehicle. The one with HID has already had one bulb replaced by Toyota and now has the same on/off issue. The one without HID has had no problems. I read above where someone said NHTSA has decided there is no safety issue. If there is no safety issue, then why can police issue a ticket for defective safety equipment (one headlight not working)? Anyway, after reading all of the posts, I am going to register with the FTC, NHTSA, and sign on with the Girard Gibbs class action suit. I will give Toyota a chance by calling the 800 number but I had an experience with them before and was not satisfied with the results.

I just had a headligt replaced on a 2007 toyota prius for $254.00 any class action lawsuit I would like to be a part of. Toyota should correct the problem. Sometimes while driving at night my light would go out, lucky for me each time my husband was driving ahead of me and called and ask that I turn the lights on and off, of course it would come on then. I to ask the question must someone die before something is done?

Dave B - Since when has the Prius been made in America?

First off I own a 2007 Prious Touring model with 60,00 miles and originally purchased it to "save money". I had a friend notice recently that my headlight was out but when I checked it there was no problem. That was weeks ago and now, one police warning later, much to my chagrin have attempted to replace the bulb. Easy right...LOL?

After visiting 3 auto parts store to no avail I went into the dealers parts center with the offending light which was easy to remove, if you're an amazingly strong elfin waif of course. This feat was accomplished by my boyfriend's strength, my small hands, a compact mirror along with instructions found on the internet (http://www.wikihow.com/Replace-Headlight-Bulb-on-2005-Prius). I was so proud to have been able to bring in the bulb and was expecting to overpay at least three times as much as the $10 average price of bulbs at the auto parts stores. As I was given the price I stood and stared waiting for the guy to quit joking around. After several moments of this faceoff I realized he was serious and wondered how this guy was able to tell me a light bulb was $159 with the tax and keep a straight face. I found that exact bulb online NEW for $49.99 on ebay (Toyota Prius 06-09 Philips D4R XenEco Xenon BULB) and a similar bulb at 2 for $49.99 (http://www.highperformancebulbs.com/hipexed4rhid.html). I'm going for the twofor since I'm pretter sure I'll be replacing the passenger side soon.

Just hoping this fixes the problem and isn't like the ones described above being a constant intermittant problem.

Hope this helps those who'd rather do it themselves. I can't see how the deler can justify charging so much for a lousy bulb and add insult to injury by charging labor when two non-mechanical people were able to access the bulb on their own within 15-20 minutes with just a screw driver to remove the dust cover. Which by the way removing the dust cover is the only instruction given in the owners manual. Everything else was removable by hand but the online instruction were what did the trick.

I just finished replacing the driver side HID on our 2006 Prius. We also own a 2001 and 2005 that have done fine with 190k miles between them, so I am suprised to see the amount of difficulty everyone is having. Using a mirror and being astounded with the work my dentist does while seeing everything in reverse, I got the bulb replaced in about 45 minutes, counting the 20 minutes travel to Advanced Auto parts. I bought a $23 bulb. After reading these posts, I now wish I had found a "better" bulb. I found that inverting the rubber boot helped in getting it into place, then pushed and prodded it into position. We used to take gallbladders out in much the same way, but never had to put one back!

after reading all of the entries regarding the 2006 HID headlamps I called the Customer Experience Center at Corporate Toyota.
The agent was very respectful. He told me that since last year's complaints about the Hight density lamps,,, they did research and determined it was a problem specific to the bulbs and not to the central computer module. They don't feel the module should be replaced but said that they did reimburse people who intially had the central module replaced. Now they have reduced the cost of the High Intensity light to be comparable to a normal halogen head light. It appears I will have to pay for labor to replace the bulb. I have been told that in order to have any future follow up support from Toyota regarding my headlights... I will have to go to a dealership to have it replaced. I have a call in to one of my local dealership's Service Manager. The other dealership I went to over the weekend did not tell me anything about the Customer Support Program for the 2006 Prius HID headlamps concerns.
I'll let you know what happens. If you have this concern too, I recommend you call Corp Toyota Customer Service Center at 1-800-331-4331

Thanks for all your good comments here.

Mine: 2005 with HID driver side lamp out

When I remove rubber boot I see some kind of silver metal cap over the lamp base and can't seem to get that off of the lamp base. Trying to work this from the top so may need to take bumper cover off, etc.. and remove entire lamp assy as dealer suggests. Is there a site or instruction for this process?

TIA.

We are having the same problem with our 2006 Prius. We love the car but were astounded by the dealerships price of $350.00 to replace the passenger headlight. Any luck confronting Toyota?

Hey, same issue here three years ago with my 2006. My car was less than a year old and I replaced my headlights twice and on the third visit to the dealership, a mechanic admitted its a common issue. So instead of replacing it again, I called the 800# on Toyota's site several times (over two weeks) and they finally arranged to have my headlight replaced again. I was the annoying customer caller, but needed to be. They also refunded my money for the other two replacements (I had to fax in receipts) and they made sure to throw in the disclaimer that the money was "an act of goodwill" and not an admittance of an ongoing issue.

I'm positive they replaced something other than the headlight because I haven't had the issue since 2007.

On another note, I don't think the Prius headlights give off enough light. Any fixes, please let me know.

About the 2004 headlights. According to the owners manual you don't have to take off the bumper to put in a new headlight. I had my local mechanic do it for thirty bucks. I put in the hot blue lights and now one blew out or maybe the wire is loose but check out the manal and you will see that you merely take off the front cover and then unplug the connector. The unplugging of the connector is tricky and I don't know the name of the tool. Its kind of a sideways plier. So yeah either do it yourself with the user manual or bring it to the local guy who you trust, (there are so many bad mechanics out there) and have them do it.

I got my letter also. This does not fix the problem. The lights still go out and Toyota makes $300.00 in parts, not including labor. Its a pacification of the REAL problem. I'm glad that those who paid for unnecessary repairs are getting reimbursed, but we still need to keep up the pressure for a recall on this problem. As I read the entries, seems to me that even replacing bulbs does not correct the problem as many times folks have to have work done several times? Join the Class Action @ http://www.girardgibbs.com/Prius.asp?_kk=prius%20headlight%20hid&_kt=c46...

Well it seems I just joined hundreds of Prius owners on on this "rip Off" on replacing a headlight bulb. First off at 80 years old, I am not crawling under the car, or open the hood to go inside of the engine compartment unit to fix it even if I knew how. The next real problem was stopped by police and detained about 20 minutes checking to be sure my car was not stolen??Then I turned the deadlights on & off and sure enough the left (drivers side) went on, but the officer said I must give you a ticket as there was no light on when I was stopped. I had to have the light replaced in 24 hours to have the summons voided out. So off I went to the dealer. who are nice enough to the tune of $150.00 for the bulb, plus $80 for labor plus tax. for a grand total of $250.00. I was tole this was a real bargin as the bulb has a $300 retail, and Toyota people are giving us a break. I think ( hard to recall) but in my 62 years of driving, I might have replaced a seal beam once, if at all. Oh, I forgot the passengers side looked dim and they suggested I replace that bulb also. So whatever money I saved on gas ( reason why I bought the 2007 Prius,
just went out the window). As soon as things change around a bit and see what the other makers are doing, like Ford or Chevy, thats when the Prius gets traded in. I see by the hundred of letters posted here, it is a waste of time, to even consider Toyota to do a recall I see it does not pay to be loyal and have all your work done at the dealer, like oil change, tire rotation etc.So this is where we get seperated, and for good reason

You need a screwdriver (phillips) and if you have a power screwdriver, even better.

You need to remove the plastic cover from the front bumper. It's held on by about 14 screws. A few on top, but most on the underside of the bumper. You will need to lay on the ground, on your back to get at them, so you want to do this INDOORS.

After the bumper trim is off, you will see the screws that hold the "Headlight Assembly" in place. That's the whole unit that contains the headlight, turn signal and parking light.

You unscrew and pull forward (gently) the whole headlight assembly, and then just take the bulb out of the back, it's a quarter-turn lock.

Then re-assemble.

There is NOT enough room behind the headlight to remove it while the headlight assembly is mounted in the car.

With a power screwdriver, about a 20 minute job. If you have to take all those screws out and back with a hand screwdriver, you will need to go slow, or have a very strong wrist.

I have a 2007 Prius. Both headlights have gone out, one at about 35K (which was under warranty). The second went out at about 39K and I called Toyota. Toyota (via a woman named Heather who said she is a Chicago regional manager) led me to believe they would cover the cost of the repair because this is a "known issue," but I had to pay for the repair upfront. It cost $230 at a Chicago-area dealer. After the repair, Heather said Toyota would cover parts at $150, but not labor, which is not what they initially led me to believe. The bottom line is this is a Toyota problem - clearly they purchased and installed subquality headlights - and there should be a recall. Contact the National Highway Traffic Safety Administration hotline at 888-327-4236 or online at http://www-odi.nhtsa.dot.gov/ivoq/index.cfm to file a complaint, even if you've done the repairs. I just did. Also, if you have this problem, make sure you contact Toyota headquarters at 800-331-4331 to make them pay for at least part of it. Heather, if you're in Chicagoland, is at x73833. Just don't believe her if she says Toyota will pay for the whole thing.

Same problem with the headlamps. Add me to any list for a class action suit.

Same headlight issue. We took it to the dealer and they said the headlight ECU needed to be replaced. That was under warranty, but after an entire day wasted at the dealership getting the car serviced the problem still remains. Now they want $500 to replace the headlight - similar to what other people have stated here.

I just submitted my contact info to get updates on the class action suit, thanks for posting the link.

http://www.girardgibbs.com/Prius.asp?_kk=prius%20headlight%20hid&_kt=c46

2007 Prius headlights went out on a dark mountain road.

I also love my 07 Prius, but the headlights have become horrible.

One shuts down. I turn them on and off and they both run fine for a while. Then it shuts off again or maybe the other shuts down or sometimes they both go off and I'm driving in darkness.

I'm currently at the dealership and they ate jut giving me the run around. It's horrible. They quoted 4 hundred plus dollars to fix it and I told them exactly how ridiculous that was. I have been a loyal customer of Keyes Toyota and done all my servicing there, that will nit be the case now.

The service guy asked if I had had any other problems with the car!!!! Haaa. I said no. But I guess they think that makes this maaaaajor problem ok. So lame!!!!

Extremely Beyond Words Frustrated,

Dx

I've had the same problems with my Xenon headlights on my 2006 Prius. Replaced them for big bucks after only 18 months and now one of them is "winking" and fading off and on again. Today, I got a letter from Toyota that helps some - they are issuing $150 refunds for folks that have replaced this before at a Toyota dealer; also they found their dealerships replacing a related part when it was not necessary (an ECU, or Electronic Control Unit) - for which they are issuing full refunds. Also, they have cut the price on the bulbs going forward.

I'm guessing with more than 100,000 miles, you are out of warranty. But I would ask the dealer if it is under warranty before authorizing work on it.

My first guess at it is that you are developing a short in the push button itself. It would be like developing a short in the ignition switch in any other car.

In the meantime, you can try this: try pushing and holding the start/stop button down for at least 3 seconds and see if that kills the engine. Pushing and holding the button down should kill the engine even if the car is in motion. If that doesn't kill the engine, you should have it looked at right away because that's a safety feature.

I need to replace my passenger bulb on 04 Prius. I have repositioned the washer reservoir, and I can reach the back of the headlight, but I can't see enough to remove bulb. What's the trick?
Will

2007 Prius...same tune here...both sides go out intermittently. Got the letter from Toyota too. Lost my job last year and can't afford to pay the huge price to replace the light bulbs! Hubby is not mechanically inclined in any way and is 65 years old...likely would not want to even attempt the task.

I think we will try the recommendation of calling the cust experience line as recommended above and see if we can get any satisfaction!

For people using the method - not removing the bumper cover ( I gave this a good try, but couldn't do it).

In retrospect, there was no reason the wiring harness needs to be removed - When you turn the black plastic cover off, It can stay attached.

If I hadn't tried to take of that first plastic connector, maybe I could have done it this blind way

For the method without removing the bumper cover (I gave it a good try, but couldn't do it)...

In retrospect, the first plastic electrical connector probably doesn't need to be remove. Just turn the black plastic cover 1/4 turn counter-clockwise and remove both together.

The next connector (shiny metal if you can see it, just inside the larger black plastic cover) is also a 1/4 turn counterclockwise off

Knowing that (you probably wouldn't if you use the blind method) should make getting that on and off more easy.

I have the same problem with my 2006 Prius. You cannot tell me that this is just a bulb problem. First the left headlight goes off and immediately will go back on as soon as you turn the lights off and on...on other days it's the right headlight that does the same thing. The scariest thing is when BOTH go off at the same time! When you are traveling on a dark country road, this is DEFINITELY A SAFETY ISSUE. I am livid. Toyota dealer told me today that there is no recall, just a notification...get this: they will give us a break and only charge me $150 a bulb each instead of the usual $300 each and oh, yes it will cost $200 in labor to replace them. I asked if it wasn't the bulb, but an electrical issue, would they refund me the money for the false fix. They said no. I do not have $500 to fix this issue. It is definitely a Prius issue, a Toyota issue and they ought to fix it.

this is going to be a class action suit

Same problem regarding headlights. I have replaced 8 bulbs, with an aftermarket bulb from O'Reiley. Cost $8.40 BUT the lights go out after a wk or two. Very fustrating!! I finally broke down and went to the dealer today. $506 was the cost to replace both bulbs. What a rip off. I guess they figure we will get tired of replacing them and the hassel of the work to replace the bulbs. What a headache. Please add my name to your list. Other than this problem w the headlights, I have no other complaints about the prius.

I have a 08 Prius level 2 so I don't think I have HID, just regular. Can u clerify bumper cover. Is this the entire plastic piece tha goes around the front of the car?? I am pretty handy but this sounds relaay complicated?

Bill

I have the same problem with my drivers side light in my 2006 prius. Ive been unemployed for a year and cant afford the 200 dollars to fix the one bulb even though its a lot less than a lot of you paid. If they are going to put in 200 dollar light bulbs, they better last 10 years! My teenage daughter drives the car a lot and I shutter when I think of the possibility of both lights going out on her! I would never have bought the car if I knew about this problem.

On top of the light bulb issue, my mileage has dropped to about 39 gallons a mile for no apparent reason. The dealer supposed checked all the possibilities and found nothing wrong. So...I should have bought a Honda or a Jetta I guess. Im very disappointed!!! And I miss my Ford Escape!

Going to try the Toyota Customer Service line tomorrow. Thanks for the tips and please post any updates anyone gets!

Julie

Go to this link and become a facebook fan to stay informed. http://www.facebook.com/pages/Prius-HID-Class-Action/195351592664?ref=ts
Info Page - HOW TO CHANGE THE BULBS FOR $50

Have xenon lights, passenger light on some days off others on, random. Took it to dealer 3 times, of course each time it was on. They said, "can't help you when nothing is wrong". I showed them that the bad light burned in a yellowish color while the drivers light was clearly white. Service guy claimed not to see what I was talking about, so I went into the mechanics area and asked one to take a look, he immediately noticed the different color and suggested they test the temperature that the bad light was putting off with some light temperature testing gizmo they have. THAT WAS THE KEY! Once they tested and saw that the bad light was burning way too hot, the service dick/guy said, "OK, it seems your light is defective, it is covered under the 36/3 warranty, we'll have it finished in 10 minutes". Good luck!

Go to Auto Zone to buy your light bulbs, for standard bulbs it cost $15.99, for a set $22.99. For High Intensity it cost $17.99 for a set it cost $34.99 and install them your self, it's not hard just a little tight.

PAY ATTENTION closely. A 2006 Prius. Headlight out while driving. Common in ANY car. Flicked to brights, worked; then 100% out while driving in darkness. Flicked back; 1 headlight worked. Flicked brights; 100% worked, then 100% out while driving. Naturally, flicked back from brights backed to 1 headlight. Dealer did between $400-$500 in repairs that Corporate Toyota covered. Dealer said problem was a bad bulb of course AND FAULTY resistor for the assembly. I apologize to all fellow Prius owners that I haven't filed a complaint with the NHTSA yet. I hope no one has crashed yet and got hurt. I'm busy so I haven't filed, but I promise I will between now and 4 July. I believe this is potentially way worse than the break story going on and I don't want anyone to lose their freedom forever!!!

Julie, I don't want to give you advise due to legal reasons, but I can tell you that if one bulb goes out it should get fixed right away. I made the mistake once of turning my brights on after mine burnt out and then all my lights eventually stopped working (see my more lengthy post on here). My repairs were between $400 & $500. My factory warranty was still good at the time, but I was lucky corporate Toyota paid for it because normally a light bulb isn't covered due to it being a user maintenance item. Just remember though parts are costly, but your child's life is priceless.

Many models of Toyotas are made in America you dinosaur.

I am beginning to wonder about some of these horror stories about $500 headlaps.I called my dealer and found that a halogen bulb is $45 and labor $80.00.A far cry from what I read here.I have a 2007 Prius and as far as I know,the 2004-2009 models are the same.

Really ~ cause I owned a Ford Contour in the late '90s and I had one repair after another (living up to its moniker, fix or repair daily) ... I flipped my lid when I was told that the headlight components were going to cost me $450 EACH to replace. I had pinhole leaks in each, with dirt accumulating. I asked if they could just open them up and rinse them out. No go. That was the last straw for me!

I have a 2008 Prius and suffering from the same blinking headlights issue and also being ripped off by dealer for dealing with it and also being declined a refund by Toyota, Well this is my last Toyota vehicle! good luck for them finding customers for the scam boxes!

This should cause a product recall and not be pushed into customer pockets!

I do hope this does not end causing deaths and accidents like any of the other defects they swept under the rug with other cars, I do encourage those of you having these issues to file a report with the NHTSA or any other pertaining goverment agencies

2007 Prius. Wow, I thought I had done alot of research on the Prius before buying this used one for problems. I must have missed this site. If I had only have known! We are repeat Toyota customers for years.....they have now lost our business for good. Dec 2009 got our 12 volt battery replaced (no problem)...next day....headlight problems, just like everyone else is reporting. I drive at nite and in the early morning hours in the dark..and when they first went out that next day, I almost went off the highway. Panic was the only word I can think off and I quickly turned off and on lights and they came back on....I thought I must have hit something on steering ...and calmed down and went down the highway to only have it happened again.......on and off I did the lights........this happens every morning/nite......took it for the oil change at 53000 miles yesterday at Larry Miller Toyota in Peoria, AZ.......I told them the problem the day after the 12 volt battery was put in...the light problem.....service guy said it was a common problem they are having with Prius'...........said it would cost $500 to replace.....we don't have $500........and beside the cost was outragious. They said it is mostly the labor cost....and they would have to take my bumper off the car.......what?????.........we wished we never bought this car. Previous postings.....saving gas vs getting lights replace....?? I will buy American next time...it will be my first, but I can't waiting to get rid of this car.......I posted a complaint with the gov't and now I am going to call Totoya customer service who aren't at all friendly...........

just take the top of the fuse box off. unscrew the rubber cap (it says open-close on it). After you unscrew the rubber cap, remove the latch (small silver metal peace). Pull bulb out.

take the new bulb and put it in the correct spot. put rubber cap back on (tricky) with the 3 prongs out of the slot so you can plug it in.

TOYOTA was not making money off parts and to create more cash flow they made their cars more complicated with as many different little $100-$500 fix it jobs as possible. Anyways the prius lights suck. They will all start to go out. The only hard ones to change are the headlights.

2006 Prius.... Passenger light goes off. I turn the lights off then on and it goes for a while then does it again. I have been told, the bumper has to come off and itis $300 per light. I thought I was alone, now look at the lenght of all the emails hear. This is huge! Toyota needs to step up to the plate. The news media does not know about the headlights or they would be all over this. Otherwise, I have no complaints about my 2006 Prius. Just the blinking headlights... I don't have $300 or $500 to replace them and I am "not" going to pay that price. I'll throw myself on the floors of their showroom floors and have a fit before I pay that price. Who do we call? Can't we all write CNN or something?

I just resolved my headlight issues (2006 Prius with HID) so figured I should share my experience.

The headlights started having problems about 6 months ago (mid 2009, about 35k miles) - faint flickering and occasionally going out. When one of the lights went out (both were affected) I could just flip the headlights off and back on to fix it. The problem got worse over time, up to the point where they would go out every couple of minutes.

After reading the Prius forums, I decided to buy a set of HID bulbs off of eBay, $50 for the pair and listed as "TOYOTA Prius 06 07 08 09 Xenon HID D4R head Light Bulbs". I swapped out the bulbs myself, which only took about 20 minutes, but it was definitely a very, very tight space in there.

The problem seemed to go away for about a month. Then the headlights started to go out again. Except this time, rather going out randomly, they went out whenever the car would change speeds (e.g. going over a speedbump, turning, braking). I tried reinstalling the bulbs but it didn't fix the problem.

Last week I finally called up the local Toyota dealer (SF Bay Area, South Bay) and they were aware of the problem with the 2006 Prius HID bulbs. I brought the car in, paid about $120 for the inspection, and they
replaced the bulbs under warranty. Luckily I had saved the old bulbs. It would have otherwise been $150/bulb + labor.

So far it seems like the problem is gone. I was fairly convinced that it was an ECU problem after installing the aftermarket bulbs, but now it seems like installing new factory bulbs fixed the problem.

I have the same problem with my 2005 prius driver's side headlight. I appreciate the comments above. Please add me to the list for complaints. My dealer quoted me a price of over $700.00 for the one side lamp and computer module. This is rediculous!!! I am going to nurse mine for as long as possible.

Which Toyota dealer in SF Bay area. My right head light has this problem. Quote to fix is $500. I also have a 2006 Prius

The only relief I got was a letter from Toyota relating that they would only charge me $150 for the bulb dropping quote to $350. Outrageous for changing a light bulb!

I just replaced the drivers side headlamp on my 2006 Prius with a replacement bulb from the automotive isle in walmart. It works fine. $20.00 and an hour of labor (my own) was all it took. So far so good. If you want info on how to do it, send me an email topham7403@aol.com

ANOTHER PRIUS HEADLIGHT VICTIM ...absolutely no help from dealer... wants to sell me a $300 bulb ... it would probably fix it for a while... then all over again. Toyota needs to step up to the plate and issue a recall and fix. This is nonsense...

My 2004 Prius just started having issues with the headlights about 6 months ago. I had just taken it in for a major service, and I had no idea about this problem until I got pulled over.

At first, the Driver's Side headlight would just go out, no flicker, no fade. A quick flip of the light switch seemed to remedy the problem- it would come back on as bright as ever. Then, after a few weeks, when I would flip the switch to fix the Driver's side light, the Passenger's side would inexplicibly go out. A few more flicks of the switch and both would come back on perfectly fine.

I decided that I would have the dealership look at it when I took it in for the recall 2-3 days ago. I took it to the San Francisco dealership on Geary where they have obviously (from the above reports) seen this before, yet they still tried to tell me that the bulbs were 'burnt out'. On top of it all the dealer was very condescending and rude, and I doubt he even looked tested the lights.

They told me that it would be $250 for each bulb and minimum $155 service fee. I can't afford this- I just got laid off last month. Also, from the other reports, it is VERY CLEAR that replacing the bulbs will not fix this situation.

Last night I had to drive from San Francisco to LA to visit my family. BOTH headlights went out numerous times, while I was driving alone and in the middle of nowhere on the freeway. The only reason I didn't crash was because there was a full moon out and luckily I could see the road. I had to repeatedly flip the switch to get the headlights to come back on. (As always, they are very bright and in otherwise great condition.) I eventually pulled over to wait until the morning so that I could continue driving.

It is definately NOT the bulbs. I don't know what it is, but is not the bulbs. I'm frustrated, worried, and don't know what to do.

My wife and I both have 2006 Priuses and over the last 18 months five headlights have gone out. Cost would have been $500 each time but complaining to Toyota Corporate got them to cover #3 and #4 under warranty, pay for #2, and reimburse for #1. We are still arguing over failure #5 and so far Toyota is not owning up to their responsibility.

It's a sad fact of life for our country, that the most "American" cars on the road are Volkswagon and Honda. The 'big three" have outsourced the majority of their production overseas.

Hi,
Here is the story.
I needed to change a bulb in my new 2008 Prius. I have HID bulbs.
I went to Toyota dealer...
Bulb - $170. Labor - ~$350 plus tax
Why so expensive, I asked. The technician replied, we need to remove the whole front bumper cover and all the plastic covers, then remove the head light and only then we will be able to change the bulb. It's 3 hours labor, he said.
Total of $520 to change the bulb.

This sounded "rip-off" to me and I went to Internet.

First of all, I found on ebay a pair of exact same bulbs (compared by Toyota part number) for $72 + $5 shipping (for 2 bulbs). $77 total. (if you have regular non HID lights, it will cost you probably $20-30). It's better to have a pair, cause they might have a difference in intensity and color with the older one.

Now came the labor part. I checked on youtube and found some videos how to remove the bumper cover and to change the bulb..... Not too complicated and about an 1hr of work.
However, accidentally, I saw a video of lady changing the bulb in 3 minutes, without removing the bumper cover. There were some comments about "small women hands" and that man can't do it...

I've decided to give it a shot.

I did it on the passenger side. They were right, it is not very convenient to get there with my hands. I've removed some piece of plastic that directs the air to the windshield fluid tank(just 1 clip). I've removed the tank itself (this part took me the most time, until I realized what tool I needed to squeeze the plastic clip - long nose pliers), 1 nut and 1 clip.
Removed the back head light cover (just 30 degrees turn of the round cup), removed the power cable of the bulb (slight turn as well).
Then I used a check-up mirror ($7.99 in Autozone). to see the clips that fix the bulb opened them and changed the bulb! Voilà!
IMPORTANT! You MUST to wear gloves (I used medical check up gloves) when you touch the bulb.

Tools: wrench(I used metric #10, it worked for me), long nose pliers, gloves, small screwdriver to open the clips and check up mirror.
Expenses : mirror - $7.99, bulbs $77. I have the rest of the tools.
Labor 1/2 hour (I am sure next time it will take me no more then 15 min)

Savings - ~$450!!!

P.S. if you need to change the bulb on the driver side, just remove the fuse box cover or the fuse box itself if you have really big hands.

Hope it will help you some day....

I'm late on this chain so forgive me if I'm repeating some things.

Yes, it's clear the dealerships and Toyota will make their excessive profits. There is a better way.

1. Buy the bulb on the internet and change it yourself. Enough people have done it including me and my friend. First bulb replacement is a learning experience and will take you about 45minutes. Second bulb will take 10mins. Here's one place to buy the bulbs -- http://www.carhidkits.com/account/login.html
There are other sites as people have mentioned on this blog board.

2. As for the comments about outsourcing and why Toyota and other car companies use certain suppliers for the car components, the inside fact is that they would rather used the best vendor, BUT there are two forces at work. First, they have pressure as public companies to reduce cost. Part of that blame is on all of us consumers. Second and most revealing is that non-US companies like Toyota would rather not buy from US suppliers (like Delco), but they have to due to politics and all that buy American stuff. Their data consistently show that American suppliers have the worst quality. Fact is there are fewer and fewer American suppliers (due to lots of reasons including US regulations and other constricting policies) thus Toyota has to buy from whoever is left....which aren't much.

The current rash of "recalls" is a result of the Toyota situation. Car companies want to be safe and so they're reporting every issue. Most of those issues are due to what I described above. Expect this to be the on-going norm. There are no exceptions so EVERY car company has issues.

Jeez, you hybrid drivers are so cheap! You save hundreds on gas, and experience minimal repair costs (other than the not-stopping thing), and whine about a light bulb. High tech=high cost.

Moron.
American cars are crap, built by over-paid union workers who think the world owes them something, engineered and marketed by con artist.
Bring back quality to US production & engineering and inherently sales will return.