I replaced the hybrid battery in my 2005 Prius today & when I disconnected the 12v battery the wrench arced & I assume that I blew a fuse. I have looked, but have not found anything. I hope I am missing something obvious & would like feedback from anyone with an idea of what to look for. Thanks!!!
There's a 120 amp fuse on the positive terminal of the battery. If that's blown, nothing works -- not even the dome light. If the dome light works, turn your attention to the proper installation of the orange safety plug on the traction battery. A lot of people forget the last step of pressing the plug down after swinging it up to the vertical position.
You do not say if the car is still working or not. If the car is ok then all you did was short the 12 volt battery for a split second and no harm done. If the car now has problems the likely fuse you have blown is in the red covered connector to the 12 volt battery. There should not be damage to any fuses in the front of the car. When working on the 12 volt battery always disconnect the negative - ground wire first and re connect last to help avoid this potentially dangerous situation. John (Britprius)
As you say the car is not operational, the first obvious test is to use a voltmeter, measuring from the battery's positive terminal to an unpainted metal ground point on the body. You should measure 12V there. Make sure the negative cable is connected tightly, both at the battery itself and at the body. Then move to the 120A MAIN fuse, and confirm you measure 12V at both ends of the fuse. If that is good, move to the main relay/fuse box next to the inverter, take off the lid, uncover the positive dedicated jumpstart terminal (hiding under the red plastic hinged cover) and see if you measure 12V there. Somewhere between the point at which you no longer measure 12V and the upstream point where you are able to measure 12V is the location of your problem.
Thanks for the help. It was a bad cable grounding the 12v battery to the body. I always miss the obvious. This is a awesome site that has cost the dealers millions.