Help Needed - Headlight Switch Assembly Replacement

Discussion in 'Gen 3 Prius Care, Maintenance & Troubleshooting' started by Madjik_Man, Apr 6, 2025.

  1. Madjik_Man

    Madjik_Man Junior Member

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    Hello

    I'd like to just open with I've searched the forum for the PDF repair manual and can only find this one 10-page document (that's always referenced) which only shows me bumper removal and seat disassembly:

    2010 repair manual in .pdf | PriusChat

    I've searched Youtube (only found a Gen 2 vid, which does not relate) as well as the Nutz About Bolts sticky thread and do not see the help I need.

    I've also searched this forum for a switch assembly replacement walkthrough and could not find anything either.

    Issue: Low beams, both sides, stopped working simultaneously. High beams and marker lights work.

    Diagnosis:

    • Wiring and connector plug at the bulb appear fine - base on the fact that the high beams and marker lights work, it is my assumption the wiring and connector plug are both fine.

    • The bulbs are fine - bought a replacement pair and same issue: no low beams but still have high beams and parking lights.

    • The fuse is fine - the 40A fuse for the low beams, horn, shift control and back up lights seems fine based on the fact that the horn, shift control, and back up lights work. Only the low beams do not.

    So that leaves me with the switch assembly probably being bad.

    I ordered a non-OEM part from Amazon that has good reviews (and a 30 day return policy).

    Now the problem is how do I remove the cover trim that surrounds the switch assembly. On my 1st Gen Tacoma it's just two screws you access by turning the steering wheel. On the 2nd Gen Prius video walk through, it was by pulling the access panels on either side of the steering wheel and then removing two torx screws that hold the airbag in place. Then from there you remove the steering wheel which then gives you access to clips holding the cover time on.

    But I removed those two access panels and there's no torx screw (or anything) that's obviously holding anything in place that would give me access to the cover trim or switch assembly.

    But if I turn the steering wheel there are these two points on the cover trim (see attached photos and red circled area). Is this how I pop the cover trim off in order to access the switch assembly?

    If not, can someone walk me through how to replace the switch assembly and/or upload the repair manual (all or just the relevant section) that would show me.

    Thank you in advance.

    IMG_3691.jpg IMG_3692.jpg
     
    #1 Madjik_Man, Apr 6, 2025
    Last edited: Apr 6, 2025
  2. PriusCamper

    PriusCamper Senior Member

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    I've never worked on this problem before, but I recommend going to a wrecking yard and pulling the replacement part to get some practice on how to do it before you work on your own car...

    Judging from the pictures though, maybe one of those round stickers that obviously don't stick very well got inside there and caused this problem?
     
  3. Madjik_Man

    Madjik_Man Junior Member

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    Yeah unfortunately the yards around here get picked clean super quick.

    And I can't imagine one of those stickers could make its way to interfering with the switch assembly in any way. The switch contacts are contained inside the stalk and the electrical connection is on the bottom of the assembly (pointing towards the floor).

    I do appreciate your input very much.
     
  4. Tombukt2

    Tombukt2 Senior Member

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    To get the steering wheel off the generation 3 remove the access panels where your light and wiper stalk stick through You take a piece of plastic or your finger and those things pull out and you pull them off the end of the stalk and set them on the ground then inside you will see a straight fat piece of metal that looks like it's part of a paperclip It's a u-shaped clip that goes from the top of the hole that you just took the cover off of down to the bottom You grab it with a pair of pliers and pull it out and down or lift it up It's a real pain in the butt instead of two screws like in the generation 2 they replaced the screws with this bent metal clip You may need to look at some videos they're probably some online I'm not the only person that's taking the steering wheel off the generation 3 It's pretty routine actually It's a sucky system to mount the wheel but oh well You want to have everything aims straight ahead when you do this after you get the pad off you can follow the instructions for the generation too you'll need to remove the orange and black plugs off the back of the airbag lifting up the yellow clips popping off the wires undoing the wires at 12:00 off of the clock spring then undoing the 19 mm nut wiggle the wheel and it's off and you set it on the ground on top of the airbag and now you're staring at the clock spring and attached to the clock spring or your light switch and turn signal I'm assuming you're replacing this whole assembly It's clamped on to the tube look behind.
     
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  5. Madjik_Man

    Madjik_Man Junior Member

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    (Also - to every one reading this (thank you) I will of course disconnect the negative terminal off the battery before messing with the airbag.)

    Thank you. Now that I'm looking at it after reading your post I do see a retaining clip of some sort on either side behind the access panels. But these aren't the access panels where the wiper stalk and headlight stalk stick through. On the driver's side nothing is sticking through this access panel and on the passenger side the cruise control stalk sticks through that side's access panel.

    See the images attached.

    Are those two retaining clips holding the airbag assembly in place? I can't wrap my head around how this is being held in place. I will search for videos on Youtube.

    And I'm only replacing the headlight assembly/stalk. They're two separate parts. And on the Gen 2 video I saw, each stalk/assembly is clipped in place - so I'm assuming it's the same on the Gen 3.

    Driver's side:

    IMG_3693.jpg


    Passenger side (cruise control stalk sticking through):


    IMG_3694.jpg
     
  6. Madjik_Man

    Madjik_Man Junior Member

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    Edit: doesn't look like I need to remove the steering wheel at all.

    Hard to tell from this video but it does look like I just push in on those tabs circled red in my first post. Then pinch the lower steering column cover trim in and pull down. Thus separating the covers off the column and gaining access to the switch/stalk assemblies:

     
    #6 Madjik_Man, Apr 6, 2025
    Last edited: Apr 6, 2025
  7. Tombukt2

    Tombukt2 Senior Member

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    Yeah you can pull them off like that if you want You changing just the headlight switch or the whole assembly You might want to go to a junkyard and look at a car and somewhat a disassembled state The plastics I've had off the generation 3 they just pull off I guess I thought there was a screw on the bottom piece of the plastic to hold it in place on the assembly If not you can feel it if it's not there then they're just pull apart clips they don't need you to do anything you just rip pull them up and pull the bottom one down usually I don't do that till the steering wheels out of my way because I'm working on other stuff that requires the steering wheel to be off If I'm taking the master combination switch assembly off I'm sliding it over the steering wheel shaft but if you're just replacing the stalk that has lights or wipers on it I think you can take that off without sliding anything over the steering wheel shaft. And if that's the case well there you go But that seems to me like that's going to take a whole lot longer time and a bunch more screws personally usually I replace the master combination switch because in my car I'm adding the fog light ring and all of that to turn on and off fog lights which on generation 3 you may or may not have I can't remember. So I'm usually taking the steering wheel off If you don't have to do that then you won't have to take the horn button off either I don't think If you can finagle around to get your switch assembly off whichever it is wiper or lights I guess you could work that way seems to me be like working around my backside to get to the front but yeah okay this is a 15 18 minute job here at my house generally speaking on the cars we own here I just ripped the steering wheel off of the generation 3 to put it on my generation 2 last week out of a persona sitting here in the yard The clips you have pictures of you grab those with your needle nose pliers and you pull out and you lift up you'll get it if you try it a couple of times try pulling on the pad as you're lifting up the thing that looks like a giant paper clip when you get it lifted up and pulled back a little bit one edge of the pad will start to come undone now you got to reach over to the other side and do the same thing on it when you get it just right the paddle come flying off and dropping your lap almost it'll be hanging by the wiring If you feel the need you'll undo the 12 volt to undo the yellow clips on the orange and black connections to the airbag I don't my car is just turned off and the remote's not near it click click drop the wires in the steering area hole that you just created removing the pad then I undo the other two cord steering wheel buttons and cruise control but if you can get away without taking that off by all means have at it it'll just take you an hour and a half to do the work versus about 20 minutes with the stuff out of the way but that's a personal call
     
  8. MAX2

    MAX2 Senior Member

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    Strange choice.
    Why for example not an integration relay?
    Or why not wiring from the Main Body ECU?

    Do you have a car with LED?
     
  9. Madjik_Man

    Madjik_Man Junior Member

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    My car does not have LED, daytime running lights, or fog lights.

    Admittedly my next step was based on my experience with my Tacoma. Same symptoms.

    Can you elaborate on the relay because I don’t have access to a wiring diagram. Is this relay strictly inline with the wiring for the low beams?

    I also didn’t examine any of the wiring coming off the ECU - will take a look at that.
     
  10. Tombukt2

    Tombukt2 Senior Member

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    So you have a regular generation 3 with h8 and h11 bulbs in place halogens or their equivalents or something? If so this is a car that had wiring harness problems from the factory I think for some reason there's an updated part maybe have a look I think there's a wiring harness that may be in your future That's just for the headlights
     
  11. Madjik_Man

    Madjik_Man Junior Member

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    It is the basic 2010 Prius with 9005 bulbs. Nothing fancy.

    I did read about that TSB in my research but that was focused on bulbs burning out quickly (which mine do). But that TSB didn’t address the symptoms I’m experiencing: no low beams at all (went out on both sides simultaneously after working just fine the day before)
     
  12. MAX2

    MAX2 Senior Member

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    Four wires go from the Headlight Dimmer Switch Assembly to the Main Body ECU.

    Conventionally, by shorting these contacts to ground, the low beam, high beam and side lights are switched on.

    Therefore, you can use the input contacts in the Main Body ECU and check the inclusion of external lighting options by shorting them to ground.
     

    Attached Files:

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  13. MAX2

    MAX2 Senior Member

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    The output control signal comes from the Main Body ECU via the contact group of the board to the green wire, which goes to the integration relay. The relay in turn sends power via two wires to the right and left side of the low beam via the purple wires. Outputs HLPR (1) and HLPL (2).
     

    Attached Files:

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  14. Madjik_Man

    Madjik_Man Junior Member

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    Thank for the diagrams and explanations.
    I’m praying the new stalk solves the issue and I don’t have to dive into this wiring.
     
  15. Madjik_Man

    Madjik_Man Junior Member

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    Ok, as you suspected it was not the headlight switch/stalk.

    So forgive my lack of electrical prowess here.

    1. I believe the Main Body ECU is behind the left side dash, behind the power mirror adjustment switch... above the small fuse panel, correct?

    2. I'll figure out how to get to it but once I do, I'm not sure what you mean by "check the inclusion of external lighting options by shorting them to ground." How would I short the four wires that go from the Headlight Dimmer Switch Assembly to ground to test it?

    3. In your second post above you mention the purple wires running from the HLPR (1) and HLPL (2) outputs. Assuming nothing obvious is wrong what else could I test for in this scenario.

    Edit: I pulled the integration relay and everything passes visual inspection. Connectors and wires all look good. Is it possible the relay goes bad?

    Thank you. I appreciate it. I wish I knew more about electrical on vehicles.
     
    #15 Madjik_Man, Apr 11, 2025
    Last edited: Apr 11, 2025
  16. ChapmanF

    ChapmanF Senior Member

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    Certainly it's possible. I would leave it connected and test with a meter on the green wire connecting the body ECU's HRLY output (2C pin 32) to the relay's HL4 input (1G pin 9).

    If that signal changes state as expected when you turn the switch on and off, that would suggest everything is ok as far as the ECU and the relay isn't responding to the signal. If, on the other hand, you don't see that signal change, something is funky between the switch and the ECU.

    ... and of course if the signal changes at the ECU end of that wire and not at the relay end, something's happened to the wire.
     
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  17. Madjik_Man

    Madjik_Man Junior Member

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    Ok. I'm a complete noob when it comes to electrical although I do have a multimeter (Fluke 107)

    So if I'm reading your post correctly:

    Set my meter to Volts (DC).

    Do I put the red probe in the 1G Pin 9 contact? If so, where do I put the black probe? (sorry if this question made you cringe, I'm really trying to learn electrical diagnostics). Then I turn the headlight switch and look for a change in the voltage reading? If there's a change in the voltage reading then it means the connection between the ECU and integration relay is fine.

    So then I have to try and access the ECU's output 2C Pin 32 and perform the same test?

    In this thread: 2011 Prius low beams not working. Help please! | PriusChat

    Posters chimed in and said start with testing the connector at the bulb. If I remove the connectors from the respective bulbs, set the meter to Volts (DC), which contact should I put the red probe on and which contact should I put the black probe on? Or does it not matter because this is a ground-switched system (if I stated that correctly).
     
  18. ChapmanF

    ChapmanF Senior Member

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    You can put the black lead on any unpainted body metal. Sometimes there will be a clip attachment for your lead, so you can clip it onto a nice unpainted bolt head or something and then have your hand free.

    It's a negative-grounded system. Ground is not 'switched'. The 12 volt purple wires running to the bulbs are what is switched (by the relay).

    Now, the wires running from your stalk switch to the ECU, the switch connects those to ground when turned on. So it "pulls down" the respective ECU inputs when turned on.

    The green wire between the ECU and the relay, I'm not totally sure whether that works by going to +12 for on, or pulling to ground for on. That's why I cleverly said "if the signal changes state" when you turn the switch on and off, so I could sound like I knew what I was talking about without actually committing to which way it should change. :) Anyway, with your meter on it, whichever way it is when your switch is off, you should see it go the other way when your switch is on.
     
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  19. Madjik_Man

    Madjik_Man Junior Member

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    Thank you for this reply. I appreciate it.

    I'll report back. In tears probably, but I'll report back nonetheless.