Traction Battery, from beginning to end

OK, here is the beginning. Got the red triangle and red car with !, and other lights. Autozone scan says loose gas cap, hehe. Traction battery charge indicator rapidly changing blue to green and back. Error reset, by disconnecting 12 V cleared lights for about 10 mi. 140K miles and am original owner, am pretty sure the traction battery is fried.

Where to start? Mini VCI/tech stream, multimeter, just replace the whole thing.... I understand that mini VCI and multimeter tests will find the problem cell(s), however, replacing bad cells may cause balance issues and assume that other cells may soon fail.

Am thinking to start with visual inspection and multimeter voltage test of cells without battery removal, if that's possible. Assuming I find the bad cell(s), the next decision will be on replacing cells or the whole pack. Am also considering just ordering a rebuilt or replacement pack and just skipping straight to the end. Also, my daughter continues to drive short commutes, not sure this is good thing. Comments/suggestions?

 

Primary codes at autozone were P0441 and C1241. The 12V battery checked out OK. These codes have been with me a long time resulting in check engine light.

Am getting Panglong OBD2 to use with Dr. Prius app, "

 

Understood, I'll be posting the Dr. Prius scan results, hopefully in a few days. Was tempted to just replace pack with that $1600 pack and skip to the end, but I would be missing out on all the fun.

 

Typo in initial post, should read 240K miles. Got Dr Prius battery readout, attached. I see #5 block with lower voltage and higher resistance. I also see low resistance on blocks 6 and 10. I understand that there are 2 modules, 6 cells each, per block. Therefore, I believe I have at least 1 failed module in block 5 and the low resistance in blocks 6 and 10 may well be the result of two more failed modules.

Am considering purchasing 3 modules now. My thinking is that I may do the voltage and resistance tests on the 6 modules in blocks 5, 6, and 10, rather than testing all 28. Replace the bad modules and balance. Am also considering purchasing rebuilt for a little less than 600 or finding one at a junk yard. Thoughts?

 

Thanks, hopefully that is all it is. Looking to minimize down time as I'm continuing to drive. To remove battery, clean the posts and busbars, and replace, may result in similar down time? If I have it out and apart that far, I would feel obligated to at least check those 3 modules. If I have replacement modules on hand, then I would avoid being down for at least another 3 days to receive replacement modules. Thinking that if it turns out that I don't need them, or all of them, I may return or sell them. See them for 21 on ebay. Another concern I have is skipping testing and reconditioning all 28 modules...

 

Yes, original battery with 240K mi. The scanner not finding codes was the initial autozone scan, which i believe is irrelevant upon Dr. Prius scan. Was hoping that the Dr. Prius scan may save equipment costs (charger/discharger) and/or hours for reconditioning all 28 modules.

 

Appreciate the advice. The new pack is 1600 and this is an 05 with 250K mi, not sure that makes economic sense. My plan now is to order 1 module for $21, pull battery, check voltage on each mod., replace the low volt mod in block 5. Flip every other mod and run a wire down each side to balance and soak the copper contacts on bus bars in vinegar. Wait about 20hrs and put back together and put back in car. Anyone care to hedge bets on a percentage of success? I give myself a 75% prob of success. If the red triangle does pop back up, then I'll buy the rc carger/discharger and recondition all 28.

 

Thanks for the input / advice. Looked at those prolong grid chargers, bit pricey. Looking at alternatives here and see where an HLG-80H-C350A, about $50 delivered, can be used to charge and an incandescent bulb can be used to discharge. Since I'll have the pack out for cleaning of bus bars and replacement of module, I'll cycle while out and blow a floor fan over the pack. Looks like I should plan a week to complete the cycles.