2046: the perfect gen 2 prius

This is a thought experiment on how to make a 2006-2009 Prius last another 20 years in Minnesota.

20 years of driving at 12k miles per year will net 240,000 miles. The gen 2 prius has already proven that it can make it to the 300k-500k mile range. This is a list of parts and tasks that will need to be replaced along the road to 2046.

If I had the means, I would go to the southern United States (Florida, Texas, Arizona, California) to find a rust free candidate. Fly out with a one way ticket, bring Dr Prius and an OBD2 adapter. The vehicle you buy and drive back needs to have a Dr Prius life expectancy score of 50% or greater to make the return journey.

Focus on a 2006-2009 model year. The odometer on 2004-2005 Prius stops at 299k and we want to drive well beyond that. Rust free is a must for this car to last to 2046. Leather seats hold up better than the cloth base option. Touring models will have an extra plate on the front McPherson struts (save this plate!).

Install the prius offroad lift kit and sienna sway bar links when you return to Minnesota. Get the vehicle Lanolin undercoated (e.g., Fluid Film, Woolwax, Surface Shield). THIS IS A MUST. I've seen 400k mile Prii that were coated from the dealership new and they look IMMACULATE.

Wheel bearings will need to be replaced every 10 years or so. The steel bearing galvanic corrodes to the aluminum knuckle. Dorman part number 698168 & 698169 for easy replacement of knuckles.

Fuel pump will die eventually. It is integrated into the fuel tank and is not a serviceable part. Swapping the gas tank is the 2026 option, but eventually these will become scarce. Put an inline fuel pump from a hot-rod or tuner with a fuel filter. This will go in the engine bay where the fuel line quick disconnect exists behind the inverter. Wire the new fuel pump into the existing fuel pump relay.

Combination Meter (speedometer) will go dark at some point. Replace the 16v 100 ohm ESR capacitor with a 16v 200 ohm ESR capacitor.

Replace mufflers and catalytic converters as they rust out.

For the Hybrid Battery, I would love to sell you a rebuilt pack every couple of years. At some point, the ROI for getting the new Toyota pack is better. With an average pack life of 14-21 years in our climate, budget for two Toyota factory replacements.

Good luck and see you on the road.