I bought a 6 year old TSpirit (with sunroof) from an authorised Toyota dealer in Kent. One (business) owner, full Toyota service history and a verified 45,000 miles. The dealer gave the car a 3 month warranty. Four months after I bought the car, I became aware of a rattle coming from the dashboard directly in front of me. Small road irregularities would produce a sound like two pieces of metal tapping against each other. When stationary, if I pulled and pushed on the steering wheel, I could hear - and feel - a small clunk. I returned to the original dealer who said (I paraphrase) "it's probably something loose in the dash and - anyway - it's not covered by warranty." I contacted my regular Toyota dealer (Jemca in Croydon) who I'd been using for the past 10 years with my earlier Prius - and a Corolla before that.
Jemca Croydon said it could be the lower steering shaft (£385 fitted) or the upper steering column (over £1000). See pic. The Workshop Controller at Croydon said "these Gen 3 Prius are common for both noisy bearings in the upper steering column, and even more so for the lower steering shaft universal joint". He added that "the Gen 3 Prius did not have a recall for this. Although they do suffer with a knocking issue they were not found to fail, hence there was no recall."
Jemca Croydon diagnosed a worn / knocking lower steering shaft. Croydon 'negotiated' with the selling dealer and I paid Jemca Croydon £60 to have it replaced. But the tapping noise continued, albeit at a reduced volume. Croydon said that it had to be the upper steering column.
I contacted the Honest John website. The reply was: "Tell the Toyota dealer who sold you the car that for it to have worn so badly in 4 months, the fault must have already been developing on the date you bought the car and because of this the dealer is liable to repair it free of any charge to you."
I contacted the Citizen Advice Bureaux. They advised: "Under the Consumer Rights Act 2015, the goods purchased were not of a satisfactory quality. This means it is reasonable to expect that the goods are free from faults, be fit for purpose, last a reasonable time and be safe to use. These are your statutory rights by law. Goods are covered for up to 6 years from point of sale, under the limitations act. This is separate to any guarantee, or warranty you may have, or returns policy which the Trader advertises, or has stated. Repairs that are carried out should be free and any replacement should be on a like for like basis."
I contacted my local independent garage and they said no steering shaft should ever wear out in 50,000 miles. Further, I could not have worn it out in four months, the previous owner must be responsible for 95% of the wear. The concluded that the selling dealer should replace the part free of charge.
I contacted the selling dealer with this information and they replaced the upper steering shaft free of charge.