Prius Battery Replacement Kit (GenII/GenIII) with NEW custom cells

It was a little confusing that the page in the bound instruction book, as well as the printed page, were the same. However, I'm done and pleased with the initial results. A few observations, in no particular order other than the way I remember them.

- There is no explanation for why 8-1 and 8-8 are not connected until last, just before the 7-2 disconnect.
- The 7-2 module disconnect is a bit wonky how the wires get so bunched up, but I don't know how else to route the wires.
- Although there is mention of the black covers not being important as to order, there's no mention that one should be careful not to break them during removal (because they'll be used later for final installation).
- It does not seem there is a reason to wait to put the temp sensors on the appropriate modules during initial layout. Going back to clip them on was a pain.
- There's no mention of which side of the bus bar to bolt the 7-x side to, while on the 8-x side it's very obvious which side of the batteries to put the ring on.
- There's no mention of removing the old wires connected to the orange plug on the bottom of what I think is a battery controller.
- Only half of the bolts were supplied to secure the new batteries down. There should be some mention of using the old bolts and bolt every hole. The illustration shows all holes filled, so I just reused the original bolts.
- With all the detail in how to remove the trim, between step 29 and 30 is just a huge step. If the manual didn't go into such detail leading up to removing the battery (plenty of youtube videos show that part), it's odd that there's not even a mention of removing the old batteries before starting with lining up the new batteries in the now empty battery case.
- It would be nice if there were a list of all the tools needed. I had read through the instructions, but missed the torque wrench. No big deal, but it might be for someone else.

Overall, I'm pretty happy with the install. From start to finish, getting interrupted several times for stuff, I'd say it took me 5 hours. I've never pulled the battery module out or taken much of the trim out before, so most of this was completely new to me.

Now to take pictures of the old batteries and sell them on craigslist!

 

Hi all.....I'm a noob to hybrids. I just purchased (financed) a 2004 Prius with 127,833 miles on it. (pictured) It's been great so far, but I know eventually the HV battery is going to go. I about had a heart attack when I saw the cost of new batteries and what dealerships want you to pay.....I shop around alot on the internet (that's how I found PriusChat ) . I have found a former Toyota mechanic in my area that will do an install for $450. I am having no issues with the Prius currently.....it was well taken care of but has never had a new HV battery. My questions are:
1. Are reconditioned hv batteries really worth it? I have found a company that sells them for $995, and they send a return shipping label to return the core.
2. I intend on keeping this vehicle for more than 5 years.....should I just go ahead an buy either a conventional HV battery or try 2k1Toaster's
version? I don't know that the installer I found would install it since it's a little different. I'm a little old lady that can't do it myself. Money is obviously a concern for me and if I can avoid it I sure don't want to go into hock for $3000 more....

Thanks in advance for the replies....

 

Welcome to PriusChat.
Stay away from companies selling reconditioned batteries. They quickly replace failed parts with other old parts and do not spend the time needed to properly balance and recondition the battery pack.
Some trusted users here sometimes do a proper job as a hobby and sell their refurbished batteries.
Your battery pack may well last 5 years or more. If you really want to extend the battery life you may want to consider the Prolong reconditioning system from Hybrid Automotive. Your mechanic or a trusted friend should be able to install the harness.
@Raytheeagle can advise further

 

Welcome to Prius Chat .

Keep in mind that your new to you Prius is over 14 years old and there will be things that will require repairs .

While the hv battery is one of those things, getting to know a good hybrid mechanic in your area will be your best bet from the sounds of it.

You’re about an hour and a half from one of those guys: @3prongpaul .

I’d bend his ear a bit. If I were in your position, I’d set some money aside for the inevitable repairs.

I have the Prolong equipment and share it with 2 other members here (we also loan it out locally from time to time). While it works for us, a new hv battery might be a better bet for you.

Good luck and keep us posted .

 

So totally stay away from reconditioned HV batteries altogether, right?

 

Thanks for the welcome! Yes, I am starting to "stash cash" already for the inevitable. Tell me more about Prolong please....

 

Here’s my thread on the process:

2010 Prius II HV Battery Reconditioning

There are several other threads on the topic.

Happy reading .

 

The Hybrid Automotive company owner @jeff652 is one of our trusted members gee.

 

My 2005 Prius had 193K when I got the red triangle of death. If you live in the LA area, Longo Toyota has the best deal on a new Toyota battery. I used their online parts to start the process, and then called. I was able to pick the battery up at the dealership and leave off my core. So, there was no shipping charge, no core charge. Total cost with tax was $1804.

Be aware this is only the new cells and cables. You need the ECU and contactors and frame from your old battery.

 

Just thought I would share that I am another supporter for this kit after reading all 25 pages and doing my own research/pricing options. Just placed my preorder for my gen 3! @2k1Toaster does the October eta look like it will be on time?

 

There are other parts you will need to switch over from your old battery besides the ones mentioned here. Plus you will need to properly prepare the old core incuding applying the rubber mats and securing harnesses to prevent shorting.
Also dealer has a right to refuse your core if it has been tampered with.

 

What constitutes a tampered core? About two years ago I replaced the two smelly vent tubes with some silicon tubes. Any idea if I would have issues if I end up buying a new oem replacement?

 

Look for TSB #T-TT-0365-15 (Rev)
It lists what a dealer should look for to disqualify a battery from a warranty repair—that should give some idea.

 

However, a warranty repair is a totally different beast.

The criteria that might disqualify a warranty repair may have absolutely no bearing on a customer paid for replacement HV battery.

Some dealers have tried it on, but they are apples and oranges.

 

Since the core is returned to Toyota I suspect the same rules apply.

 

Provided all 28 modules are genuine OEM (and not some kick-off or alternate modules) why should it matter?

 

Here is the original:

 

Many "refurbished" packs use modules from different generations in the same pack. Why should Toyota accept that franken-pack?

 

Naysayers have used a battery pollution argument against EV's. So, the supposed reason touted early on for the $1350 core charge was Toyota only cared about those old packs being recycled correctly and not ending up in landfills, etc. Guess that was false.