What is this rear suspension component part name / number?

Looks like the auto-leveling sensor, for starters. The elbows seize, and then something has to give.

 

Or some sort of splint. It's like a broken bone. put 2 or 3 slim metal rods across the break, as long as possible, wrap liberally with wire along the length, butter it all up with 2-part epoxy.

Checking that the ball joints are free-moving should be in the maintenance schedule; grit and road salt kill these things. Easiest way to check, and distribute the grease, is unbolt one end, work the joints.

 

No code?

Headlight Auto Leveling Sensor Issue? | PriusChat

 

It's a link for the headlight leveling sensor. The swivel joints are seized and ruined.

Toyota sells the link only as part of the sensor. You can find just the link from the aftermarket.

Or just remove the broken link and zip tie the sensor arm about at half travel and not worry about it.

Posted via the PriusChat mobile app.

 

The function is to keep the LED headlights aimed properly though.

 

That coat hanger wire is not going to hold long. The bends will open up, change the spacing (before it eventually falls off), and if the spacing is wrong, the sensor is wrong, and the headlights won't do what they are supposed to. It may wear a groove into part of the other pieces before it fails. Not good.

In this thread:

Headlight level sensor 'tie rod' broken | PriusChat

they refer to this part

(go to Amazon, search for "Febest 0123-GRJ120-KIT LINK, HEIGHT CONTROL SENSOR, REPAIR KIT 48906-35010")

which is a generic linkage that can be adjusted to 75 mm center to center. Here is the manufacturer's page:

FEBEST - 0123-GRJ120-KIT - Link, height control sensor, repair kit

which says that it fits 2004-2009 Prius.

See that OEM part number? If you search with it other similar parts will be found. However, all the ones I saw were "never heard of that company" Chinese parts. From what I have seen online, Febest seems to be the German equivalent of Dorman, so not so great in quality either. That said, it is just some threaded metal, nuts and bushings, and it isn't doing anything tricky or handling much of a load, so it should be good enough. Just be sure to lube it once and a while.

The real part is $57 at one of our nearby Toyota dealers:

Height Control Sensor Link Sub-Assembly Rear #48906-35010 | Autoparts.toyota.com

 

48906-35010 might even be cheaper here:

Buy Genuine Toyota 4890635010 (48906-35010) Link Sub-Assy, Height Control Sensor, Rear. Prices, fast shipping, photos, weight - Amayama

On west coast Canada I'm seeing roughly $50 CDN, full price with shipping. I've used them multiple times for items up to around $100 CDN, never any extra charges, say duty/tax.

 

That replacement part looks good.

The rust, not so good.

In the second picture there are two bolts facing up which look like the nuts have already rusted on. Would be a good idea to treat that rust before it gets worse. At least hit the rustiest areas with some squirts of "Fluid Film", or a similar product.

I understand that as NE cars go, that one isn't terrible. From a California perspective, that amount of rust would be grounds for not considering that vehicle for purchase.

 

I’ve also replaced this recently. I’m in the UK so my car failed MOT as this part had snapped. My local Toyota wanted £774 to replace it! I bought the part off eBay and fitted it myself. Use WD40 or similar on the bolts first.

 

Maybe Toyota should edit the maintenance schedule, replace “check driver’s floor mat”, with “check headlight levelling mechanism”. Seriously, every couple of years:

Unbolt one end of mechanism, work all elbows, reinstall bolt.

 

There were no LEDs on Gen2. But there is a lever even on my Gen2 with halogen lamps.

 

Interesting, perhaps your car came from the factory with HID and somewhere along the way the car was converted to halogen.

 

I may have got it wrong. My Gen2 doesn't have a height sensor. The sensor was for HID, I don't have them.