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2006 Prius bad battery pack?

Discussion in 'Gen 2 Prius Main Forum' started by fella39485, Jul 21, 2021.

  1. fella39485

    fella39485 New Member

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    I just got a 2006 Prius for $900. I knew it would be a project, and I'm just looking for some help from the Prius community.

    I was told that the hybrid and 12v batteries are both bad. The 12v one wouldn't charge past 10v, so I got a new one of those. The hybrid battery case really looks like it has been tampered with, so it seems very likely that is an issue.

    Upon starting the car as I got a ton of error messages, lights, and it wouldn't turn the engine on or ready up (as expected). I hooked it up to Dr. Prius and found the pack voltage at 158v, and it looks like some of the cells are not working right. I also got error codes P3000 (which I'm not familiar with) and P0AFA.

    I also tried putting the car in maintenance mode to run the engine alone, but with the pack being so dead, it wouldn't start and the MFD screen showed the word "Problem" really big which I thought was kind of funny.

    My next course of action is replacing the entire battery pack and management computers as an assembly. Does this seem like the problem to you more experience prius people? I've only owned a few of these. Also, is there any special programming or coding that has to be done to pair the new battery pack to the car?
     
    #1 fella39485, Jul 21, 2021
  2. fella39485

    fella39485 New Member

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    Hopefully, some of these attached images are helpful:

    20210721_093633.jpg 20210721_114030.jpg 20210721_114038.jpg Screenshot_20210721-113542_Dr Prius.jpg Screenshot_20210721-113624_Dr Prius.jpg Screenshot_20210721-114022_Dr Prius.jpg Screenshot_20210721-114550_Torque.jpg
     

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    #2 fella39485, Jul 21, 2021
  3. bisco

    bisco cookie crumbler

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    welcome!
    if you are going to diy this, i suggest tech stream and the service manual.

    you don't needto reprogram anything after replacing the battery. consider newpriusbatteries.com
     
    #3 bisco, Jul 21, 2021
  4. PriusCamper

    PriusCamper Senior Member

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    If you let us know what part of the US you live in, there might be someone on here who lives near you who can support you repair effort.

    And if you're lucky, it's possible that only problem with battery pack for the moment is a bad voltage sensor harness due to corrosion, which is only a $50 part and a couple of hours of work to replace. Once the voltage harness is replaced we can tell you via the Dr. Prius readings what needs to be done next.
     
    #4 PriusCamper, Jul 21, 2021
  5. mr_guy_mann

    mr_guy_mann Senior Member

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    Hello and welcome to Priuschat. As mentioned, it's not a bad idea to get a mini VCI cable (along with a bootleg copy of Techstream) from amazon or ebay and install it on an old windows laptop. That gives you OE level diagnostic software which can be very useful to get the "inf" or subcodes and can communicate with all the control ecu's on the car.

    Also, the negative voltage readings indicate that there is problems with the small orange voltage sense wires from the HV battery blocks to the battery ecu- or maybe the orange connector at the ecu. Corrosion damage to the connector and the ecu pins isn't uncommon, but the harness is available new and the ecu can be found used on ebay- plug & play. You MIGHT be able to salvage the present pack- or not. Good luck.

    Posted via the PriusChat mobile app.
     
    #5 mr_guy_mann, Jul 21, 2021
  6. fella39485

    fella39485 New Member

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    I did end up ordering a battery pack from eBay because I wanted to have one ready by the time I got back from my little vacation. This is a refurbished one (risky I know), but it was used in a car for a year and taken out because the car was wrecked.

    I put the pack in today the car did start, but I'm getting weird behavior from the Prius and some similar symptoms from before. I was able to drive it around a bit but had no power in reverse and no power until the ICE started. (Seems like no battery power at all but ICE could crank hmm) I also observed the battery getting hot (up to 150F!!) and the fan running, and the state of charge was jumping in between 100% and 20% sometimes on Dr. Prius. I also still do have P3000 and P0A80

    Could the inverter be bad? What is this? I do have a pretty advanced scanner that might be able to get the subcode on P3000, but I won't be able to try until the morning.

    Feedback appreciated. Thank you
     

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    #6 fella39485, Jul 28, 2021
  7. dolj

    dolj Senior Member

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    Those screen shots show a very unhappy hybrid vehicle (HV) battery. A bad battery would be more likely than the bad inverter based on that Dr. Prius data.

    I'm not sure how you can have 100% SoC with only 198.05 V.

    You likely have one or two modules each with a reversed cell.
     
    #7 dolj, Jul 29, 2021
  8. mr_guy_mann

    mr_guy_mann Senior Member

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    Did you clean any corrosion from the bus bars and torque the nuts to specification? Did you inspect the orange connector at the battery ecu (and the ecu pins) for corrosion? Did you clean the battery fan, and does it work?

    Unfortunately those DrPrius screenshots show a weak and deteriorated HV pack. Sub codes aren't going to help right now- your data shows huge voltage differences on two different blocks. Normally you see 0.3V difference under most all conditions.

    Posted via the PriusChat mobile app.
     
    #8 mr_guy_mann, Jul 29, 2021
    Last edited: Jul 29, 2021
  9. fella39485

    fella39485 New Member

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    Thank you guys so much for the valuable feedback and advice.

    I am in contact with the guy who sold me the battery. He's super understanding and willing to give me a full refund. I must note the battery case was pretty bent up during shipping which I assume could cause issues, but I was really hoping it would work. The car did start and seem to have electric motor power for a little bit before it eventually wouldn't move in reverse and the engine would start before moving forward.

    While starting a search for another pack, I also don't want to rule out other possibilities yet. The battery pack was sitting in the hot sun for about 20 minutes before I put it in the car, so that should explain the high temperatures. The weirdest behavior I observed was the SOC changing from 100% down to somewhere in the 20s or even bouncing up to the 80s. It would instantly do it as well while just sitting in park. Could this point to a control module or sensor instead?
     
    #9 fella39485, Jul 29, 2021
  10. dolj

    dolj Senior Member

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    Possible, but I doubt it. My money will be on the 4 modules in blocks 8 and 13. Find the bad module or modules there and replace it/them with modules that match closely with the other 24 modules and you'll be in a much better position.
     
    #10 dolj, Jul 30, 2021
  11. Peterhans

    Peterhans Junior Member

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    #11 Peterhans, Jan 5, 2022
  12. Peterhans

    Peterhans Junior Member

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    Interested. You mean a bad voltage sensor harness at a module location can cause similar problems? I show internal resistance is near zero. I also have a 2006 prius with the same error codes. Now 2022 and only 69000 miles. I see one bad module and deciding what to do.
     
    #12 Peterhans, Jan 5, 2022
  13. PriusCamper

    PriusCamper Senior Member

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    yeah, the corrosion problem in voltage sensor harness is primarily if you get really weird readings that don't make any sense. If you're reading all normal except one bad module that's lower in voltage, the harness is probably not a problem yet.
     
    #13 PriusCamper, Jan 5, 2022
  14. Eddiebrid

    Eddiebrid New Member

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    hey - i recently purchased a project prius as well 2008 180k ,replace hybrid battery pack code came on...

    any suggestions or guide -
    as you can see im new to the forum.

    thanks in advance
     
    #14 Eddiebrid, Jan 17, 2022
  15. robinredd1

    robinredd1 Junior Member

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    fastest easy way to find bad models in 3 minutes
     
    #15 robinredd1, Aug 18, 2024
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