2002 Prius Battery Fix

That kinda depends on your situation. If you want to save money and have time, tools, and some research/DIY skills you could retrofit it with 2nd gen or even 3rd gen modules (all 38). If you lack the above, you could hire an independent rebuilder/installer to install a reconditioned pack. Or if you have the money and only want the very best, I would say order a new pack from Toyota.

Any of these, I feel are decent options. While I agree with most that a reconditioned battery is not AS good as a new one, I definitely believe it is the best value for the dollar. If done properly, it should be in close to new condition. You should get many more miles with it.

 

If you are doing Gen 1 battery with new modules from Toyota it may not make much difference. A new Gen 1 battery should last as long as the original one, if not longer.

If you are buying a used battery, then check what the warranty is. There are packs with 3 year warranty. Will it last as long as a new pack? No. But may be long enough for your needs.

After that, the rest is kind of a crap shoot. If you aren't too worried about reliability, and have the time to throw in a few modules once in a while, then you can just throw in your own modules. In that case just get the best ones you can afford. Most will not have any long-term warranty.
If you want to swap out all the modules using Gen 2 or Gen 3 Prius packs you will need to buy 2 of them, since they have less modules than a Gen 1 pack. This means the modules will not be matched. But it's not any worse than just swapping in a few random modules into your Gen 1 pack.

Not sure how clear I'm being, but feel free to call me if you have any questions.

 

I have a dissenting opinion.

A Dorman remanufactured battery with Gen II modules lists for $1939 at Napa auto parts. A new Gen I battery from Toyota lists for $2299 and discounts to $1954 can be found. John Elway's Crown Toyota Scion | New Toyota dealership in Ontario, CA 91761 So a new battery can be bought for basically the same price as a rebuilt.

A DIY rebuild with Gen II modules is also not cost effective. You would end up very close to the price of a new battery and have to do a lot of work.

If the car has sat for a year, all the modules are most likely junk. If the car has sat for less than two months since it last ran you could get by with a DIY rebuild. You would get really good at it by the second or third time. The Gen I batteries are now all so old and worn out that a rebuild is not likely to last long.

Brad

 

I agree with Brad regarding used gen1 packs in general.

For example, last week I had one that was sitting for ~4months. Not greta, but in the past there might have been some reasonable expectation of recovering it. But not this time. Tried several strategies just for the heck of it, but it was simply too far gone. Put in new pack instead.

 

I don't even fool with changing the gen 1 modules. I'll retrofit the whole pack to at least 2nd gen modules. The old ones are junk.

 

I'm curious. What do you charge to rebuild a Gen I pack with Gen II modules?

Brad

 

They start at $1300 with a 1 yr warranty.

 

There's a place in Texas I found on the net that charges somewhere around 1500 for a refurbished gen 1 with a warranty (can't remember how long though) with a 400 deposit and you get that back when you send in your old battery pack. They also offer the gen 2 and 3 upgrades for a bit more money. I'll try to find it and post it here for you.

Posted via the PriusChat mobile app.

 

I couldn't find the one in Texas but here's one in New Jersey (i think) and it's about the same price. Hope it works out whichever way you decide to go.

Posted via the PriusChat mobile app.

 

hi all sorry to bump this, quick question for Brad if I may.

Brad, have you had problems with gen2 modules in storage? (1year+)

or Is this only an issue for gen1 modules?

or did you just mean they will be flat?

I have a few (failed) packs in storage for future use and dont want to compromise them any further.

cheers..

Matt

 

Dorman 587-000 remanufactured, with improved buss bars, an ecm, and wiring $1599 includes shipping and return shipping for the core, AND a three year warranty.

Dorman 587-000 Reman Hybrid Drive Battery Pack Remanufactured - Core Additional | eBay

 

Hi Matt,

Long term storage is a great test. Modules that fall to 6.XX on their own through self discharge are junk that will not recover. Testing at the cell level shows that a 6.XX module will have five cells at 1.2 volts and the failed cell will be the .xx . Modules that hold at over 7.2 volts are most likely good. Kiwi can now jump all over me for that.

Storing modules in a mostly discharged state will result in more (10 to 20%) failing through self discharge. Charge the failed packs before storage.

Years ago I had Gen I modules survive over four years of storage. Those days are long gone.

Brad

 

Hi Brad

Thanks heaps for the advise, storage has been a bit of a worry to me.

I have a few packs buried deep under my cellar that have been there almost a year already (its cool and dry down there but a pain to access) not sure if I should get them all back out and grid charge each or just let nature take its course, i was hoping they could sit in hibernation for a few years, only time will tell I guess.

Kiwi yeah lol isn't he just fun

thanks again really appreciate the info.

Matt

 

sorry if i am in the wrong discussion
hello everybody , I m new on the forum, back in Europe (France) , and not much of people who knows something about working on a prius here, i am trying to solve a pbm :
prius 2 ; august 2006 ; 192000 KM , used when bought , Tranny maintenance ? 12 V battery fully charged every time i try to start but used
i had a HT battery failure, bill from toyota that i refused (2500 €), i change my self the 2 faulty elements (thanks you tube) and put back everything : 212 V on testing

when i brought my prius 2 back home the thermic was working D & R but of course electric was not working.

since then , and I checked and rechecked everything, the orange big security plug position (as mentioned by several personns) all the 3 connectors to the ECU, the connector to the Fan , even the polarity of the HT connectors ....

same old song : THE READY MODE DOESN T COME ON, NO D OR R POSITION POSSIBILITY, THE THERMIC DOESN T FIRE UP , I noticed that i don't hear the Clac Clac of relays ans that the 12 V battery is drained after 1 day if stays connected. NO error CODE on ODB device

i desinstalled one of the 2 main relay to try to test it, but i am stucked

any ideas ? any suggestions, HEEEEEELP PLEAAASSSE

thanks