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Replace Hybrid Battery -- Where to buy dead battery to repair?

Discussion in 'Gen 2 Prius Care, Maintenance and Troubleshooting' started by Wayne Walter, Jan 4, 2017.

  1. Wayne Walter

    Wayne Walter Junior Member

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    Hi. We want to purchase a hybrid battery and attempt to repair, recharge, re-balance, etc as described in this excellent and helpful forums. I'm an engineer and this all seems trivial to do after purchasing the appropriate chargers. This is for a 2005 Prius which is a Gen II battery.

    Background: My daughter's Prius battery died 18 months ago and we got a "refurbished" one from a local guy who is very nice and knowledgeable. He replaced it 2 times for free during the 12 month warranty but now the warranty is up and he wants another $1000 to start over again. There are others online that are a bit cheaper.

    This time I want to DIY and purchase a dead one and repair it and then replace my daughter's and then repair hers to keep it as a spare. I'm also considering teaching my wife how to refurbish and re-balance to help me resell them as a side business.

    Does anybody know where I can get a dead battery? So far on eBay everyone one wants the old battery returned. And all the ones that I can find are already refurbished. Research shows that there's aren't really any selection of Prius at junk yards.

    Any ideas? I'm nearly to the point of buying a refurbished one and paying the "core charge" to keep ours.
     
  2. JC91006

    JC91006 Senior Member

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    If the core charge is $600 or less, you should pay the core charge and keep it. Junk Yards will charge you about $600 for a battery, with no exchange required
     
  3. Wayne Walter

    Wayne Walter Junior Member

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    Here in the forum I read people calling many junk jards and none of them having any Prius cars for parts. Do you agree?
    I don't want to wast time calling them in vain unless it seems likely to find one.
     
  4. JC91006

    JC91006 Senior Member

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    Here in Los Angeles, where there are tons of Prius cars, will give you better results in your search. In Virginia, you might not be able to get so many options.

    Junk/Salvage yard batteries are not guaranteed to be good, they basically are a "core" that would probably have some good modules and some bad modules.
     
  5. JC91006

    JC91006 Senior Member

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    I believe there was a member here selling a complete pack from a 2015 Prius, I think he wanted $1200 for all the modules. You can possibly buy those modules and put into your working car. You'll at least have that one trouble free. Then use the rest of the old modules to play with
     
  6. Wayne Walter

    Wayne Walter Junior Member

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    Yes. I have seen ads for 28 (new?) models for $999.
    But I also want a core to build the replacement battery,
    cycle it, balance it and such so her car is drivable until
    until the rebuilt battery is ready.

    People who sell all 28 modules. Are they new? or do they
    somehow rebuild old modules?

    And I'm calling a few junk yards now to see.
     
  7. JC91006

    JC91006 Senior Member

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    You just have to ask questions on the modules they are selling. If there are 28 modules sold together, it's probably going to be from an older pack. 28 modules for $999 is not going to be new.

    Why would you want to cycle, balance a battery if you're not going to use it? You'll need a grid charger to do it properly and if you let it sit too long afterwards, it'll discharge and you'll have a pack that's not balanced again.
     
  8. Wayne Walter

    Wayne Walter Junior Member

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    Ahh to be more clear in my origin post title it says "Replace Hybrid Battery" because her cause is throwing that code right now and her battery isn't keeping a charge very good. But not totally dead yet.

    So I'm building a replacement so her car won't be out of commission for over a week while repairing her battery.
     
  9. Wayne Walter

    Wayne Walter Junior Member

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    Yayyy! I just spoke with a guy while will accept $500 for a battery from a Prius
    whose gas engine died but he kept the batter to resell. I'll get it tomorrow.
    Thanks everyone for the input.

    FYI, I tried 4 junk yards and they all said they don't have anything for me.
     
    bisco likes this.
  10. JC91006

    JC91006 Senior Member

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    You should open the battery cover and check if the serial numbers on the batteries are similar. If they are all different (I mean all different letters and number combinations), then it's just a bunch of junk batteries put together in a pack

    It would be better if you can test the module voltages, make sure they are all over 7.2 volts
     
    #10 JC91006, Jan 4, 2017
    Last edited: Jan 4, 2017
  11. Wayne Walter

    Wayne Walter Junior Member

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    Thanks for that advice! I was wondering how to check it before paying.
    What tools should I take with me? I haven't opened one up so I'm assuming
    taking phillips and standard screwdrivers plus metric sockets will be enough.
    What else? I'll bring my meter to check a few of them at least, randomly
    for voltage.
     
  12. Wayne Walter

    Wayne Walter Junior Member

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    Frankly, I'm willing to replace all the modules if necessary to have a really solid battery for
    my daughter's car. I think $500 for the ECU and SMRS and the core is not a bad deal
    even if I end up replacing all the modules. Don't you think?
     
  13. Moving Right Along

    Moving Right Along Senior Member

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    Battery modules in the same pack are going to be subjected to the same conditions, and if a few modules failed, then there's a good chance the rest aren't far behind. Hybrid experts like Carolyn Coquillette from Luscious Garage have stopped using salvaged and remanufactured batteries as replacements because the reliability is too low.

    I know you don't want to hear this, but if you want your daughter to have a reliable car, your best options are either to replace the battery pack with a new one or get a different vehicle.
     
    jadziasman likes this.
  14. jadziasman

    jadziasman Prius owner emeritus

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    I agree with Moving Right Along. New pack or bust.

    I sold my Gen 2 because I didn't want my 18 year old daughter getting stranded with a failed HV pack. My 05 had a lot of miles on it with the original pack. While I regret not taking the risk and doing a DIY install of a new pack, I wasn't driving it anymore, she was.

    But hey, if you enjoy a challenge......
     
  15. Wayne Walter

    Wayne Walter Junior Member

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    I do appreciate advice, "Moving Right Along". Still did you read where I said that I'm happy to replace every single battery module? At that point it before essentially a very solid battery, right?

    My thing is that I want to build my own battery. But just to get the core metal container that all the modules come in along with the ECU And SMRS is very difficult to get a hold of. I was faced with buying a "refurbished" battery for $600 which will likely have only 1 or 2 modules replaces and then a core charge of $750 just to keep and have my own spare battery. That is $1350. But now I'm getting a "dead" battery for $500 and will spend perhaps $1000 on all new modules. So for $1,500 I'll have a battery that's unlikely to fail for years.

    Plus, I'll have the dying battery to tinker with and refurbish myself by replacing 1 or 2 modules, then cycle charge it, rebalance it, test it out in my daughter's car, and then resell it to someone who doesn't find this kind of thing "fun". And get their dead batter and do it over and over. I wanna get my wife involved to help with doing the reconditioning process and help with phone calls since she doesn't have a day job. Then I'll help with local installations.

    It'll be fun thing for us to do together and make a little money.

    Now that you see the full plan, where are the holes?
     
  16. Wayne Walter

    Wayne Walter Junior Member

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    Jadziasman. I must be missing something. But if I replace the entire set of 28 modules...then she has basically a new battery.

    I'm considering to replace the leads to the batteries also with new ones that are more resistant to corrosion and essentially have a better than new battery. It should last for 4 years or more.

    I see guys on eBay offering 4 and 5 year warranties on reconditioned batteries with ALL new cells. But they charge upwards of $2,500.

    I will enjoy doing this myself and costing only $1,500 for a reconditioned battery with ALL new cells.

    Is that so dumb since I'll thoroughly enjoy myself saving both the $1000 and the technical work is fun too?
     
  17. Eastside

    Eastside Member

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    Don't junkyards have an internet search site for finding parts ?

    Enjoy rebuilding the pack. Lots of resources here and on YouTube. Enjoy.
     
  18. Sam Spade

    Sam Spade Senior Member

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    Do you believe EVERYTHING you see on Internet forums ??;)

    The larger used auto parts places have a network that they can search to find parts........although shipping a battery could get kind of expensive, if you could find anybody to do it.
     
  19. stockdaddy

    stockdaddy Member

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    you really just need to replace the bad module. if you can test the old modules for minimum of 4000mah capacity that will make the pack a bit more reliable. it really only takes a hour or 2 to tear into the battery pack once you get use to taking the car apart. I keep a spare module in my car & socket set in case it fails during a long trip.
     
  20. Sam Spade

    Sam Spade Senior Member

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    You have described the "holes" quite nicely in your own previous experience with "rebuilt" packs......that have failed twice on you during the warranty period. What do YOU intend to offer as a warranty on your rebuilt packs ?? What kind of insurance will you carry against liability if one of them catches fire, for instance ??

    To repeat: The modules are all about the same age. When some fail, the others likely are not far behind.

    I don't think this is a good plan at all.