Background

The 2001-03 Prius, the NHW11 model, accelerator uses a pair of potentiometers to measure the position. These two signals have to track each other or the control computer decides something is wrong and goes into a 'limp home' mode. An important safety feature, the failure mode can cause an error code but always results in the "big hand" syndrome, the car acts as if a giant hand is holding it back.

Doug Schaefer pioneered how to disassemble and clean the potentiometers and his process is described in this downloaded PDF. However, I've picked up Doug's inventory and am offering rebuilt accelerators for those uncomfortable with Doug's approach.

All accelerators are tested in my car and if there is a problem, I will replace it with another for the first year. I'm selling them for $150 including shipping with an additional, $100 core charge for returning the old accelerator and tools. Your upfront cost is $250 and $100 will be refunded when the old accelerator and tools arrive.

Replacing the accelerator is a fairly easy, do it yourself task.

Introduction

You will need:

Procedure

First configure your back and body support so you can lay on your back on the driver side floor:

In this case, a lawn furniture recliner is used with a board. Cover the board with padding and you're ready to go.

The first step is to remove the lower, 10 mm. bolt. Remember the right hand rule, use your right hand thumb to show the bolt direction and the curled fingers point to the rotation direction:

Next disconnect the accelerator connector by squeezing the latch on the left hand and rocking the connector out. Try to avoid stressing the wires by pulling on them.

Finally, remove the upper bolt and pull the assembly out:

To install the replacement assembly, loosely tighten the lower bolt to hold the assembly in place. Don't tighten it, yet. Then put in the top bolt. Be patient and avoid cross-threading the bolt. Tighten the top bolt, firmly.

Tighten the lower bolt, firmly and then connect the accelerator cable. Make sure you hear the latch 'click'. Then go for a test drive.

After a few days, return the accelerator and tools using the prepaid shipping label. You'll need to tape them down and pack in newspaper so it won't rattle.

Robert J. Wilson
9011 Randall Road
Huntsville, AL 35802
256-652-3618 (cell)