Replace Hybrid Battery Questions

Discussion in 'Gen 2 Prius Care, Maintenance and Troubleshooting' started by Mike Carambat, Feb 9, 2015.

  1. Mike Carambat

    Mike Carambat Junior Member

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    Hey folks,

    Have a 2005, with 170,000 miles and yesterday Triangle Light with VSC came on. I plugged in my ODBII and saw a stored code which said 'Replace Hybrid Battery'. Oh joy. Unfortunately, I shortly thereafter CLEARED the code, so I didn't write down which code number it was. Yes, I'm an idiot. This is a new iPhone Wifi based ODBII scanner, and I had thought clearing the codes was going to just clear it on my phone, and I'd be able to poll it again from the car, but apparently not. It cleared the light on the car as well.

    So, my questions are:

    1. I'm not 100% certain the code was valid (wishful thinking I know). So, when will the car throw another warning light now that the code has been cleared? Should I wait until it throws it again?

    2. I'm still getting about 38-40 mpg as of yesterday test driving in town. Would it be premature to pursue replacing the battery at this point, or should I wait until my mpg drops? Should I spend the $100 at the dealer to check the battery?

    3. Been wanting to go full EV with this car by putting in a larger capacity battery from a reputable EV conversion company, but don't know if they require a working stock battery as well. How does that work? Do you need a functioning stock battery if you add their larger battery pack?

    4. Or... if I went with a salvage battery, which year model batteries are compatible with the 2005?

    Thanks for any help

    -Mike
     
    #1 Mike Carambat, Feb 9, 2015
    Last edited: Feb 9, 2015
  2. bisco

    bisco cookie crumbler

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    how many miles on her?

    i would keep driving her until you get the warning lite again, should come back pretty quickly if the battery is going south.
     
  3. Mike Carambat

    Mike Carambat Junior Member

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    Just updated my post with that info :) 170,000
     
  4. bisco

    bisco cookie crumbler

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    thanks, these things are not written in stone. pay attention to your battery meter, it usually starts to fluctuate wildly as the battery fails.

    have you checked your 12 volt health?not much out there in the way of ev conversion, even diy is big bucks.
     
  5. Mike Carambat

    Mike Carambat Junior Member

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    Thanks, and yes, the 12v was replaced 6 months ago with a factory one, so I know it's good. The battery indicator doesn't seem to be acting dramatically different than it used to, however I don't know what's normal as I bought this car used 6 months ago and it might have been on it's way out already and I just never knew.

    Typcially, it gets one or two bars below where it turns green (a bar or two about the mid point) and the engine tries to make it stay at that point, fluctuating rapidly between giving the battery a charge, then backing off and letting the battery provide power back to the motors. Only regenerative braking seems to make the batteries get enough charge to go green.

    The only thing I'm noticing it's doing differently is that it goes FULL GREEN bars way more often than it used to. I used to never get a full set of greens, the top bar would hardly ever fill. Now, after a long duration stop I can almost always make it go full green with the regnerative braking. It doesn't stay green for long however, and is soon back to the mid point and starts the charge/power cycle again.

    I can travel at about 12-15mph without engaging the engine. So, I've tested the battery recently by driving the car on electric only at that low speed and I'm pretty sure my capacity has been reduced. At a 'full Green' I can travel about 1/4 mile before the level drops low enough for the engine to kick in. About the distance between two red lights on a busy street. I think I used to be able to get a full mile or so, but that might not accurate.

    Anyway, if any of this seems odd, please let me know

    Thanks,

    -Mike
     
  6. bisco

    bisco cookie crumbler

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    yes, the 'going full green more often' may be a sign of a bad cell or more.
     
  7. exstudent

    exstudent Senior Member

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    Why not get the mini VCI cable and techstream software (Amazon, eBay)? More useful than the generic OBD2 readers, as they miss a lot of codes. You can see the voltage for the module pairs. You can bleed your brakes. And many other useful functions the generic obd2 reader can't do.

    The Link has all the information about set-up and hardware requirements for running Techstream; even contains a link for a 64bit OS set-up.
    TundraTalk.net - Toyota Tundra Discussion Forum - View Single Post - Offical TechStream software thread( settings and such)

    New 12V battery doesn't always mean it's good. Lots of posts about the importance of checking it from time to time w/ a DVM (Digital Volt Meter) and recharging w/ an appropriate charger.

    Some EV conversions use the original HV battery, in addition to an additional battery, others simply replace the HV battery completely.

    EDIT:
    Gen2 (2004-2009) use the same HV battery. New will get you greater longevity than rebuilt. Assuming the HV pack on your car was original, look at how long it lasted.

    Gen3 (2010-2015), modules can fit into a Gen 2 case; you would need to swap out all 28 modules. You don't want to mix some Gen3 modules into a Gen2 case. Go to the Prius Technical discussion for Gen2, lots of good info on rebuilding HV battery packs, swapping Gen3 modules into a Gen2 case.
     
    #7 exstudent, Feb 9, 2015
    Last edited: Feb 9, 2015
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  8. SageBrush

    SageBrush Senior Member

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    Take advantage of this window in time to start shopping.
    Search this forum for the threads that have discussed the pros and cons of different replacement choices.

    All the best
     
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  9. Mike Carambat

    Mike Carambat Junior Member

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    Oh man! Never knew that existed! Thanks! Ordered the cable just now from eBay $20!!

    My local salvage guy has a 2005 battery already pulled, not sure of it's condition, and has no idea what to charge me for it. Asked me to come by and make an offer for it. Any ideas on how much? I'm thinking worst case, between my battery and the salvage one, I ought to be able to make my own rebuilt pack. I know, dangerous as hell, but I've been working in electronics my whole life and am pretty confident in my ability not to get electrocuted. :)
     
  10. SageBrush

    SageBrush Senior Member

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    ^ I might offer $20 for every month it works
     
  11. 3prongpaul

    3prongpaul Hybrid Shop Owner, worked on 100's of Prius's

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    I would not pay more than $300-$400 for a junkyard battery. How many miles were on it? how long has it been sitting? If sitting more than 2 years it's probably garbage. You cannot easily mix modules from 2 batteries unless they have the same characteristics (capacity, internal resistance etc). Just measuring voltage doesn't tell you very much. If you mix dis-similar modules the car will code again.

    This video will help with battery removal from the car
     
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  12. hybridbatt

    hybridbatt Junior Member

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    Why dont you try grid charging at 1C for 14hours ??
     
  13. GregP507

    GregP507 Senior Member

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    Two possibilities here: (1) It could be due to one bad cell, which can be replaced, or;

    (2) It's just the first one to go, where most of the rest are close behind, in which case the whole battery should be replaced.

    It's impossible to know which is the case without testing. Anyone who tells you to do one thing or the other, without actually knowing the condition of your cells, can't say for sure.
     
    #13 GregP507, Feb 9, 2015
    Last edited: Feb 9, 2015
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  14. hybridbatt

    hybridbatt Junior Member

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    why would you be against him trying????????
     
  15. GregP507

    GregP507 Senior Member

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    Because trial-and-error usually ends up being the most expensive option.
     
  16. SageBrush

    SageBrush Senior Member

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    I agree with Greg, that $400 gadget you are suggesting that might give him a few months of battery life is about 1/5th the cost of a new traction battery.
     
  17. GregP507

    GregP507 Senior Member

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    Anyone can wreck a used hybrid battery and pull out a few cells which will still take a charge. I'd only buy reconditioned cells (for what that's worth) from a reputable source (whatever that means) but I'd understand that it's probably just a stop-gap method.
     
  18. Mike Carambat

    Mike Carambat Junior Member

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    So, these batteries can go bad if not charged over a long period of time? I thought only lead acid batteries could dry up like that. I guess I'm gonna check out the salvage battery tomorrow, and if it hasn't been sitting up too long, offer him $250.

    I've also ordered the VCI cable with the Techstream program so I can check out the voltage on my current cells. Not gonna replace anything until I get some direct info on how they actually are doing. It hasn't thrown another warning light since I cleared the codes Sunday, and appears to be running ok in the meantime.

    Thanks all for the advice.
     
  19. jeff652

    jeff652 Senior Member

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    I agree, it's impossible to say for sure if our hybrid battery cycling systems will help Mike or not. We can only base our comments on patterns reported to us by our customers and our own testing. 170k miles is high, but depending on climate and driving conditions/habits it may not be unreasonably high. Based on the fact that this is the first red triangle, and that it stayed off after a reset, the odds are that if he performed an aggressive deep cycling on the battery with our products, he will get several months of additional battery life at a minimum, and very possibly multiple years. Deferring battery replacement costs for that time period can be very attractive to some people. Others may just choose to spend the larger cost upfront for a full battery replacement and forgo the additional life that their current pack has left in it.

    As an example, our 2005 Prius gave us one Triangle Light with VSC three weeks after we purchased it. This was before using our product. We reset it and kept driving the car. It was recalibrating (dropping to two red bars and force charging) almost daily and anytime the car was started on a hot day it was immediately at two red bars. After a several months of ownership we performed two deep cycles using our charger & discharger products. The pack regained 19% in usable capacity and has not had a single recalibration in over three months since:

    [​IMG]
    This is still new and unknown to a lot of people on this forum, and I get that people will be skeptical. It takes time to accept new ideas. We have sold over 1,000 of these to the Honda community that has the same NiMh battery issues (acutally much worse). We have sold over a hundred for Prius owners in the few months since releasing them. Our Patent Pending systems are making a difference in the lives of Prius all over the world.

    For every hundred chargers that we sell, two to five customers report the product made no difference for their packs. 95% odds are not good enough for some, but most people on a budget are willing to take the calculated risk. No, they won't help everyone, and there is a risk that one or two of the modules might have already failed beyond repair and need replacement, but for those that want to keep the car running with the smallest cash outlay possible, our products are regularly helping people in big ways.

    Those that do try us, usually love us. For example, here is card we received from a customer just a few days ago:
    [​IMG]

    :)
     
  20. Mike Carambat

    Mike Carambat Junior Member

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    Thanks Jeff, your product sounds great, but I wish you had a rental program :)