🔧 Prius - Front Strut Replacement

This procedure replaces both front strut assemblies. For a beginner, complete preassembled struts are strongly recommended because they eliminate the hazardous task of compressing the coil springs.

Difficulty Level: Advanced | Estimated Time: 4-6 hours

Assumption: Complete preassembled front strut assemblies are being installed.

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⚠️ Safety & Precautions

• ⚡ Your Prius has high-voltage hybrid components. Do not touch orange cables or hybrid-system connectors.
• 🔑 Turn the vehicle completely off and keep the key at least 5 metres away.
• 🧱 Support the vehicle with jack stands. Never work beneath a vehicle supported only by a jack.
• 🌀 A compressed coil spring stores potentially fatal energy. Do not remove the strut centre nut from the old assembly.
• 🔩 Replace both front struts together so damping remains balanced.
• 📐 A professional four-wheel alignment is required after replacement.
• 🔋 Disconnecting the 12-volt battery is not required for this procedure.

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🔧 Required Tools

You'll need the following tools for this repair:

• 21mm wheel-nut socket
• 22mm six-point socket
• 19mm six-point socket
• 17mm deep socket
• 14mm socket
• 10mm socket
• 6mm hex-bit socket
• 3/8-inch drive ratchet
• 1/2-inch drive breaker bar
• 1/2-inch drive torque wrench rated 20-250 Nm
• 3/8-inch drive torque wrench rated 10-80 Nm
• 150mm socket extension
• 17mm combination wrench
• 22mm combination wrench
• Small flat-blade screwdriver
• Nylon trim-removal tool
• Needle-nose pliers
• Paint marker
• Penetrating oil aerosol
• Hydraulic floor jack rated 2-ton minimum
• Jack stands rated 2-ton minimum
• Rubber wheel chocks
• Safety glasses
• Mechanic gloves

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🔩 Required Parts

HowToo sells all the parts you need for this repair:

• Complete front strut assemblies - Qty: 2 - Replace in pairs
• Front strut-to-steering-knuckle lock nuts - Qty: 4
• Front stabilizer-link lock nuts - Qty: 2
• Plastic cowl retaining clips - Qty: As needed
• Penetrating lubricant - Qty: 1

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📋 Before You Begin

• 🅿️ Park your Prius on firm, level ground. Select Park and apply the parking brake.
• 🚫 Do not place the vehicle in READY mode while it is raised.
• 📏 Measure the distance from each front wheel centre to the fender edge. This provides a useful post-repair ride-height check.
• 🧩 A preassembled strut includes the spring, upper mount, bearing, boot, and damper as one unit.
• 🧭 Arrange a wheel alignment before driving any significant distance.

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🔨 Step-by-Step Instructions

Follow these steps in order:

Step 1: Loosen the Front Wheel Nuts

• Use the 21mm wheel-nut socket and breaker bar to loosen each front wheel nut about one-quarter turn.
• Do not remove the nuts while the vehicle is on the ground.

Step 2: Raise and Support the Vehicle

• Place the rubber wheel chocks behind both rear wheels.
• Use the hydraulic floor jack at the front centre jacking point to raise your Prius.
• Position both jack stands beneath the reinforced front side support points.
• Lower the vehicle gently onto the stands and confirm it is stable.
• Use the 21mm wheel-nut socket to remove the nuts and both front wheels.

Step 3: Remove the Wiper Arms

• Use the small flat-blade screwdriver to lift the plastic caps from the wiper-arm pivots.
• Use the 14mm socket and ratchet to remove both wiper-arm nuts.
• Mark each arm’s position on its shaft with the paint marker.
• Rock each arm gently at its hinge while lifting it from the splined shaft.
• Close the bonnet before lifting the arms.

Step 4: Remove the Cowl Panels

• Open the bonnet.
• Use the nylon trim-removal tool and small flat-blade screwdriver to release the cowl clips and rubber edge seal.
• Disconnect the washer hose by hand, then lift out the left and right plastic cowl panels.
• Use the 10mm socket to remove the wiper-motor linkage fasteners.
• Release the electrical connector by pressing its locking tab, then remove the linkage assembly.
• Use the 10mm socket to remove the metal cowl tray fasteners and lift out the tray.
• The three upper mounting nuts for each strut should now be accessible.

Step 5: Support the Steering Knuckle

• Place the hydraulic floor jack beneath the lower control arm and raise it only enough to support the suspension.
• Do not lift your Prius off the jack stand.
• Spray penetrating oil on the stabilizer-link nut and both strut-to-knuckle nuts.

Step 6: Disconnect the Wire and Hose Brackets

• Use the 14mm socket to remove the brake-hose bracket bolt from the strut.
• Use the needle-nose pliers or nylon trim-removal tool to release the wheel-speed-sensor wire retainers.
• Do not pull, stretch, or twist the brake hose or sensor wire.

Step 7: Disconnect the Stabilizer Link

• Use the 17mm deep socket to remove the stabilizer-link nut from the strut bracket.
• If the stud spins, hold its centre with the 6mm hex-bit socket while turning the nut with the 17mm combination wrench.
• Move the link clear without bending it.

Step 8: Mark and Remove the Lower Strut Fasteners

• Use the paint marker to draw alignment marks across the strut flange and steering knuckle.
• Use the 22mm combination wrench to hold each bolt head while loosening the nut with the 22mm six-point socket and breaker bar.
• Remove both nuts, then slide out the two bolts while supporting the knuckle.
• Do not let the knuckle fall outward because that can damage the brake hose, axle joint, or sensor wire.

Step 9: Remove the Strut Assembly

• Support the strut with one hand.
• Use the 14mm socket and ratchet to remove the three upper mounting nuts.
• Do not remove or loosen the large centre nut.
• Guide the complete strut assembly downward and out through the wheel opening.

Step 10: Compare and Install the New Strut

• Place the old and new assemblies side by side. Confirm the spring orientation, brackets, upper studs, and left-or-right designation match.
• Guide the correct new strut into the tower without damaging the axle boot or brake hose.
• Install the three upper nuts by hand to prevent cross-threading.
• Use the 14mm socket and torque wrench to tighten the upper mounting nuts evenly to 37 Nm (27 ft-lbs).

Step 11: Attach the Strut to the Steering Knuckle

• Align the knuckle with the strut flange and insert both original bolts in their original direction.
• Install new lock nuts by hand.
• Use the 22mm combination wrench, 22mm six-point socket, and high-range torque wrench to tighten both nuts to 240 Nm (177 ft-lbs).
• Keep the paint marks approximately aligned until the wheel alignment is performed.

Step 12: Reconnect the Stabilizer Link and Brackets

• Insert the stabilizer-link stud through the strut bracket.
• Use the 17mm deep socket and torque wrench to tighten a new nut to 74 Nm (55 ft-lbs).
• If the stud turns, hold it with the 6mm hex-bit socket and tighten using the 17mm combination wrench.
• Reinstall the brake-hose bracket using the 14mm socket. Tighten its bolt to 29 Nm (21 ft-lbs).
• Press the wheel-speed-sensor wire retainers fully into their original locations by hand.

Step 13: Replace the Opposite Strut

• Repeat Steps 5 through 12 on the other side using the same listed tools.
• Keep left- and right-side parts correctly assigned.

Step 14: Reassemble the Cowl

• Set the metal cowl tray back into position and install its fasteners with the 10mm socket.
• Reinstall the wiper linkage, reconnect its electrical connector, and tighten its fasteners with the 10mm socket.
• Reconnect the washer hose and press the plastic cowl panels and retaining clips into place by hand.
• Align the wiper arms with the paint marks, then install their nuts using the 14mm socket.
• Tighten the wiper-arm nuts to 25 Nm (18 ft-lbs) and reinstall the caps.

Step 15: Reinstall the Wheels

• Install both wheels and hand-thread all wheel nuts.
• Use the 21mm wheel-nut socket to snug the nuts in a crisscross pattern.
• Use the hydraulic floor jack to raise your Prius slightly, remove the jack stands, and lower it completely.
• Use the 21mm wheel-nut socket and torque wrench to tighten the wheel nuts in a crisscross pattern to 103 Nm (76 ft-lbs).

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✅ After Repair

• 🔍 Confirm the brake hoses and wheel-speed-sensor wires are secure and do not rub the tyres.
• 🚘 Start your Prius and turn the steering slowly from lock to lock. Listen for binding, clunks, or spring movement.
• 🧪 Test-drive at walking speed first. Verify normal steering and braking before increasing speed.
• 📐 Have a four-wheel alignment performed immediately. Strut removal changes front camber and toe.
• 🔧 Recheck wheel-nut torque after approximately 80-100 km.
• ⚠️ If ABS, stability-control, or steering warnings remain illuminated, stop driving and have the system scanned.

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💰 DIY vs Shop Cost

Shop Cost: ₹35,000-₹65,000 (parts + labour)

DIY Cost: ₹20,000-₹42,000 (parts only, excluding alignment)

You Save: ₹15,000-₹23,000 by doing it yourself!

Labour rates around Sonīpat vary. This repair takes a shop approximately 3-5 hours, followed by wheel alignment.

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🎯 Ready to get started?

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