Other fuel system problem on the 2005 Toyota Prius
When other fuel system problem gets reported
Owners of the 2005 Toyota Prius report other fuel system problem at a median of 65,000 miles. A quarter of the reports come in before 50,000 miles and a quarter after 85,000 miles, from 14 reports that carried an odometer reading.
A part like this is normally expected to survive 90,000 miles. It is the 15th most-reported problem on this model year.
The mileage distribution
The reported range runs from 25,000 miles at the tenth percentile to 130,000 miles at the ninetieth, a spread of 107,685 miles across the middle 80% of reports.
A spread this wide points at use rather than design. Towing, climate, service history and city mileage all move a failure like this, so the median is a weak guide to any individual car.
14% of the dated reports were filed under 36,000 miles.
The whole distribution
| 10th | 25th | Median | 75th | 90th |
|---|---|---|---|---|
| 24,615 miles | 50,875 miles | 62,500 miles | 86,750 miles | 132,300 miles |
Read the 10th percentile as “one report in ten arrived this early”. Exact figures are shown in this table because it is the table of record; everywhere else on the site they are rounded to the precision the sample can carry.
What a percentile can and cannot tell you here
These five numbers describe the readings owners gave, in order. The median is the middle one: half the reports arrived below it. The 10th and 90th are the edges of the bulk of the distribution, and the distance between them is the part worth reading. A tight spread — say 70,000 to 95,000 miles — points at something that wears out on a schedule, and the schedule is knowable. A wide one, 20,000 to 190,000, points at a fault that hits some cars and never troubles others, which means the mileage on the listing in front of you tells you very little about your odds.
What these figures are not is a survival curve. Every reading here comes from a car whose owner filed a complaint, so the sample contains only failures: it cannot say what share of the fleet made it past 150,000 miles untouched, because those owners had nothing to report. Nor is the mileage the moment of failure — it is the odometer reading as recalled at the time of filing, which may be weeks later and is sometimes rounded to the nearest ten thousand by the person typing it.
Percentiles are shown at all only once 8 readings exist for the vehicle and mode. Below that the middle of a handful of numbers is noise wearing a decimal point, so the figures are withheld rather than dressed up.
What happens, and what it costs
Putting it right typically runs $300–$2,200 at an independent US shop. That range is an editorial estimate held in this site's failure-mode catalogue, not a figure from NHTSA, and it is a repair cost rather than a diagnosis cost.
The same failure on other years
The same failure is reported on 14 model years of this car. It shows up earliest on the 2009, at a median of 10,000 miles, and latest on the 2011 at 115,000 miles.
By volume the 2010 carries the most reports, with 43; the 2005 has 15. A mode that appears across most years of a model is usually a design choice rather than a bad batch.
If one year stands out to the left, that is the year to avoid; if the whole line sits at a similar mileage, this is wear rather than a defect in one production run.
Tick median reported mileage Solid middle half of reports Faint 10th to 90th percentile Colour how bad the failure is when it happens
What owners wrote
Verbatim from NHTSA complaint narratives, trimmed for length. The mileage is the one the owner gave.
Our 2005 prius developed a massive gasoline leak, which made it an obvious fire hazard. We drove it home, and the car was towed to the dealer, where they found that the car's plastic fuel lines that had been damaged by rodents. The fuel lines were replaced by new plastic ones. However, we live in the country, where squirrels and mice abound, so this dangerous problem will probably happen again. There are no metal fuel lines available for this vehicle; we consider these plastic, exposed fuel lines a safety hazard. *jb
About 2 years ago, on route 840 in utica, I floored the gas pedal on my 2005 toyota prius to pass a car. The prius does not have a lot of power, so flooring it was sometimes necessary to pass uphill. When I took my foot off the gas pedal, the car was still accelerating. I touched the brakes. Nothing. Finally, I pushed down hard on the brakes and got the car to the side of the road and turned it off. I have rubber mats. I thought one of them had gone under the pedal. "case solved" so I thought. Last december, again passing a truck uphill on route 840, I floored the pruis gas pedal. The same thing happened! This time I knew it was not the mat because I had drilled holes in it and attached it to the mat posts. It was inches away from the gas pedal when this happened. I pushed the brakes down hard and struggled the car to the side of the road right before the lanes merged and the truck would have cut me off (into a swamp). The brakes, with a burning smell, fought the racing car. I finally got it turned off. When I turned it back on, the gas was still racing! I turned it off again. After waiting,it started normally. It has done it…
The gas "bladder" on my 2005 toyota prius will not expand correctly. This limits the total amount of fuel that can be put into the car to as little as 7 gal. In cold weather. The rated volume is 11.4 gal. *tr
Also reported on the 2005 Toyota Prius
Headlight failure or clouding
Other brake problem
Other lighting problem
Other electrical problem
Other speed control problem
Loss of braking
How far this goes
Complaints are voluntary, so 15 is a floor and not a count of affected cars. Mileages are typed in by owners and cluster on round numbers. And the mode itself is assigned by software reading the complaint text, which is reliable in bulk and fallible one report at a time.
Questions this page answers
At what mileage does other fuel system problem happen on the 2005 Toyota Prius?
Across 14 owner reports that included an odometer reading, half were filed by 65,000 miles. A quarter were filed before 50,000 miles and a quarter after 85,000 miles. These are the mileages owners reported when they complained, not a prediction for any individual car.
How common is other fuel system problem on the 2005 Toyota Prius?
15 reports have been filed with NHTSA, about 0.1 per 1,000 vehicles. Complaints are voluntary, so this is a floor rather than a count of affected cars.
What this is and is not. These are the mileages at which owners chose to complain to a federal agency, which is not the same as the mileage at which the part fails on every car. It skews toward failures that happened outside warranty, cost real money, or frightened someone. It is still the only public dataset that carries failure mileage at all, and the shape of a few hundred readings is informative even when a single one is not. Methodology · JSON · this failure on other cars
Source Owner complaints and recall records published by the US National Highway Traffic Safety Administration, model years 1996–2027 Figures rebuilt Published by AtWhatMileage How every figure is computed