Wiper level sensor fix

So, I recently picked up a gen 1 Tacoma, and like a lot of you, I noticed the windshield washer fluid light was stuck on—even after I filled the reservoir. Most of the forum posts I checked basically said, “Yeah, they all break, just unplug it or remove it,” which does work… but then you lose the warning light altogether. I wanted to actually fix it.

So after some troubleshooting I found that the sensor works just fine and that the issue is the float inside no longer floats.

So here is a guide on how I fixed mine and a link to a 3D file I created to fix it.

How to fix a broken wiper fluid sensor in a Gen 1 Tacoma

Step 1: Remove the Washer Fluid Reservoir

From under the car disconnect the hose from the washer pump and the connector to the harness. Then you can disconnect the 4 bolts holding it in place. Then from up above you need to lift the tank and push in the two plastic tabs and you can remove the tank from the bottom.

Step 2: Pull the Sensor

Remove the connector from the washer pump and then remove the level sensor from the bottom of the tank. Give it a quick clean.

Step 3: Bench Test the Sensor

Start by connecting a multimeter to the two wires coming from the sensor (Red and Black) and set you meter to continuity. Then invert the sensor, when its upside down it should not beep. This lets us know that the issue is the float and not the sensor it self.

Step 4: Bench Test the Float
Now to test the float cut a hole in the bottom of a plastic cup the size of the sensor, shove the sensor through it, and filled the cup with water. If it beeps then we know the float is the issue.

Step 5: Open Up the Sensor

There’s a small plastic plug at the top of the sensor holding it together. Clip that off, and the you can now remove the top and the old float.

Step 6: Drill More Holes in the Top (optional)

With the top off you can see that there are three holes from the factory but also marks for three more. Take a drill and drill out three more small holes.

Step 7: Print a New Float

Using the file provided print a new float. Settings are as follows:

Material: ASA

Walls: 3

Infill: 5%

Layer Height: 0.16

Step 8: Install the Magnets

You also need two small neodymium magnets (5mm x 2mm). Mark the poles and install them in the same orientation. These should just press into place but you can add come super glue to ensure they wont come loose.

Important: Make sure to test the new float with your multimeter. If the magnet poles are facing the wrong way, the sensor won’t work. You can then mark the top of the new float before you install it.

Step 9: Reassemble the Sensor

Drop the new float into place, put the cap back on, and use a lighter to soften the plastic at the top. Then I press it down a few times with a screwdriver to reseal it.

Step 10: Reinstall and Test

Reinstall the sensor back into the reservoir, reinstalled the reservoir in the truck, fill it up—and enjoy a working washer level sensor and light.

 

Nice Work..Welcome to TW..

 

Love this detailed repair post. TY.

I have the same problem with my gen 1 Tacoma (2002). I've been able to remove the sensor and drain the reservoir. When the sensor hangs upside down, the warning light goes off so I knoiw it is electrically good. When I shake the sensor, I can hear the float moving so it is not stuck. However, it won't float. I've even tried the old vinegar/baking soda trick but that doesn't help.

Don't have a 3 D printer but your instruction on how to take apart the sensor really helps. Maybe I can just cut one to size out of foam. Also, wondering if drilling out those 3 holes may help if float? I'm thinking whatever material it is made of has aged and will no longer float.

 

On mine I took the old float out and tried to dry it/clean it but each time is just sank to the bottom of the cup so I don't think that additional hole will help the old float.

I did pick up another sensor from the junk yard today and am toying with the idea of selling these with a core exchange but I'm not sure what they would cost ($40?).

The next thing I am going to tackle is a cabin filter. I have seen what as been attempted and think that with a few 3d printed parts it should be easy.

 

Interesting plan. I have been scouring junkyards in my area but haven't found a gen 1 Tacoma. Even if I do, I am now wondering if any sensor I find will have the same problem.

Anyway, from what I can tell, it seems a new sensor is in the $75-$85 USD range from Toyota. Not sure if you are in Canada where I am but I would pay you $40 CAD for a reconditioned one.