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My headlight level sensor is corroded beyond repair. One of the prongs broke off and is still in the connector. A new connector costs about $786. It is only available as part of the harness. It looks like the connector can be dis-assembled. The front white part comes forward and the water seals in the rear are easily removed, but I cannot budge the metal part so I can get the broken piece out. Does anyone know how to dis-assemble the connector or otherwise extract the broken piece. The broken piece is deep into the connector so there is no way to grip it. The dealer wants about $2000 for a complete repair.

Try a search on this forum for leveler. I remember someone posting details of repairing the leveler sometime ago. You may also be able to get one from a salvage yard. Just get one from an 06 or later. I'm not sure if the fix was made to the 05 by Toyota.

Hi, firepa63,

Please re-read kkayser's post. Your advice is good for him to replace the sensor on his own, but his REAL problem is the wiring harness attached to the body either has a piece of the sensor's connector stuck in it or a piece of the harness's connector has broken off & remains in the sensor's connector.Either way, he needs to repair or replace the connector on the body's wiring harness.

Probably, if he gets a used sensor from a wrecked Prius that would also be a good source to get a replacement harness at a fair price too. However, I suggest to the OP that he ask permission from the dismantler to remove the harness himself or to give specific directions NOT to cut any wires to get it out [typically dismantlers take the short quick method (such as cutting things) to remove hard-to-find or expensive parts & damaging them in the process, making them worthless in the end].

See if this post help http://priuschat.com/forums/gen-ii-priu ... roded.html

Also the attached PDF file...