My 2nd HV battery died one week after warranty ended.

The deed is done! Here is a summary:

Some interesting pictures to follow...

 

Pictures during module shuffle:
Before repack: new modules perched at either end. After repack: two rejected modules gone.

Note that I pre-labeled the modules to expedite the reassembly. Compression bolts still in place.
(Note one module changed from odd to even, so its label had to be installed at the opposite side.)

And I just couldn’t reassemble those copper jumpers without cleaning them first.
(They just pop out of their flexible carriers.) Sorry ‘bout the poor focus in the “after” picture.

 

I just took a little jaunt (150 miles) to Northern Maryland and back. I did not reset the MPG after my fooling around yesterday. The cumulative MPG was at 37 (@20 miles) when I left, and is now reading 48.5 (@171miles.)
BTW, when I attempted to crank up after the Hybrid Battery reinstall, the display lit up like a Christmas tree, and the car did not want to turn off. Anyone who has read enough of the various PriusForum threads would recognize this as "Low Aux Battery", and it was. My car had to be stored outside my garage (turned into "Paul's Hybrid Battery Rebuild Shop"), and so I had to reattach the ground so I could lock the car. After five days, with the rear hatch open for most of the time, the battery was so low (7V) that it popped the overload breaker in my trusty rusty auto battery charger, and my fancy HItec charger kept reporting "battery disconnection problem". Fortunately, I still had my old 12V Prius battery that had been replaced about five years ago. (I always ask the dealer for my old parts.) I have been keeping that battery alive by periodically trickle charging it. Also, fortunately, I had not thrown away my booster cables (and I recalled that old Prius adage: "It is better to receive than to give.") In point of fact, one should NEVER use the Prius battery to jump-start another car, but accepting a boost is perfectly OK. Needless to say, the car came right to life, and rest is history.

 

I'm sorry it took so long, but...
here is the Final SpreadSheet:

I do believe that the blocks are pretty well balanced.
One casual indication of this, as far as I am concerned (and I am a retired Electrical Engineer) is the fact that the lowest voltage block is not settling on any one or two blocks. It is constantly changing. The highest voltage blocks change a little, concentrating near the ends of the stack. This, I believe should be the norm, even though I do not have a great deal of observation time under my belt.

 

Update:
The vehicle now has over 380K miles on it, and is in the possession of my son. I did buy a grid charger, and it has been used every few months, to great effect. Now, after buying a Chevy Volt (used, of course. They don't make 'em any more), my son is keeping the Prius as his "beater", since it has a trailer hitch, and numerous cosmetic "modifications." Lately, the old machine has been showing signs of imminent traction battery failure, so he is undertaking a module-by-module manual "rebalance", which consists of a 3-cycle discharge-charge sequence, recording each module's final capacity, as determined by the Hitek charger. Weaker modules will be replaced using one or more of four modules that I had purchased before I sold the car to him. Stay tuned for his report.
I cannot say that I miss the old beauty. My Prime now is pushing 65K miles and I love it.