replace hybrid battery pack

The bad module has not totally failed yet, so simple voltage test won't yet show that it is weaker than the rest. The next step it to use a headlight bulb (12v/55w) on each module for 2 minutes and record the voltage loss. The module with the most voltage drop might be the bad one. There's alot more to it than just that, but that's the basics. Reading the sub-codes of the error codes via OBDII reader and Dr. Prius Android App will give more details about what's wrong. Check the battery ECU and the wires that plug into it for corrosion damage. I could go on and on and on....

 

I believe the car will throw the red triangle of death when the difference between the 14 high & low banks is 1 volt or greater. You probably have one or more individual cells that have gone bad as previously described. I recently had the death triangle and after reading several threads on this forum I repaired myself. I had one cell that was only reading 6.5 volts. I plan to post in another thread the complete process I used to recondition my pack. So far my pack is now working great and it only cost me $44 for the complete repair!

Let us know what you did to solve your problem?

 

Good to know, also your thread would be really useful for all of us who don't want to waste money on a mechanic, i will be waiting for it. Thanks, best regards.

 

Some way to quickly verify capacity (catching weak modules) is by discharging the battery, then charging at standstill by observing the voltage on the blocks - block whose voltage will increase noticeably faster probably contains a module with reduced capacity, e.g. 1000-2000mAh instead of 4000-5000.

If you get to disassemble the battery and test with a 50W light bulb for 2 minutes, You can also try 100W, e.g. for 1 minute, if the voltage of one module at 100W (about 6A) "flies" sharply down it is almost certain that it also causes problems when working in the car.

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I see, well then when the time comes i will try this to see which modules are bad.

But to charge the battery i use the car or i have to buy a charger?

 

the car will charge the battery within touota parameters. a charger will take it to both ends

 

Initial verification can be done while charging by auto observing the voltage through the application and OBD. But this will only give you general information that there is some problem with the HV battery. Possibly how big.



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I see, well then i will keep that in mind, thank you very much for answering.

 

No need for all the tinkering, disassembly, and light bulbs. Just a graphing scan tool. Lap top and a two day Toyota TIS sub will do. You can test it in your driveway while sitting in the driver's seat and following the procedure in the link below. Also keep in mind that when one module is going out, others usually follow. I've found it a waste of customers money to pull a pack apart and "fix" it, as it only buys a little time before the next module starts falling out.

A new battery lists at just under $2,500, and I don't know about the US market, but here and other places, Toyota gives you around $1,000 back for the old battery, and they are recycled. Total to have a battery replaced new for the C here in Japan is about $1,500 parts and labor. It takes about an hour to change.

I do the below test actually driving the car at full battery discharge amperage to full charging amperage. I find that it exercises the battery deeper than when not moving, and better identifies a bad battery.

Predictive battery failure analysis for the Prius Hybrid

 

Remove the bus bars and test each cell module after the car has not been started for a day or two. Any module in the 6 volt range is trash, replace it and reset the codes and try again.

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Toyota is not treating customers so well in Europe
No return for the battery. Used packages from broken years 2016-2018 cost nearly $ 1000. New in Toyota similarly around $ 2,000, however, assuming that 50% of the value of the car is not very profitable variant.
... We are waiting with hope that someone will come across how to replace old Toyota cells with new Tesla 21700

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