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Finally around to module reconditioning

Discussion in 'Gen 2 Prius Technical Discussion' started by Spradilak, Dec 21, 2023.

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  1. Spradilak

    Spradilak New Member

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    Hey everyone so I've been reading this forum for about 7 years now since I purchased my 08 Prius with 201k miles and the original HV battery as far as I know. The car has been fantastic and the only thing I have ever replaced is the 12v battery.

    Even now I have no issues or dash lights, aside from the annoying TPMS light that occasionally comes to visit.

    However I have noticed a pretty decent decrease in performance do to the HV battery.

    I am hard-core into RC cars so I happen to have the chargers with a total of 10 channels to charge 10 modules at the same time. I removed the battery from the car and got it set up on my workbench, got the cover off and noticed this corrosion like something spilled out.

    I had a much longer post but it got erased past here when I tried to upload the pictures......

    Anyways..what is this and do I need to do anything different?

    One time about 2 years ago I was going down rhe highway and I heard a loud pop, but thought nothing of it because I have a small amp and a subwoofer..maybe that was it. There was no smell associated with the sound but that may have been it.

    Really just looking for thoughts and suggestions, thank you so much for reading all of this.

    I can't figure out how to attach pictures, also I'm on mobile maybe that's why. But here Is a link to an imgur album of my situation.




     
    #1 Spradilak, Dec 21, 2023
  2. Tombukt2

    Tombukt2 Senior Member

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    This is common The sales modules or whatever in the middle get the most heat and have the most likelihood of leakage and what have you and you're looking at it right there surprising that didn't throw the battery leaking code but escapes me right now I just had it a few weeks ago been here done this many times so you need to find out which of those modules actually leaked usually it'll be all over the sides of the modules where the fluid or goop ran down so you'll want to replace the modules that are sitting next to each other so on and so forth so as you go through all 28 of them you're looking for that white nonsense to be running down in between two of them You want to replace those two however many there are in the rack. It can get ugly there's a way you can measure while they're all racked together if you will and you can check each module to ground and see if you have leakage If you do those modules need to be replaced they will wreak havoc on your whole build. Usually that amount of fluid laying on the tray causes the isolated battery to be leaking to the frame of the car which is trouble and codes. Good luck on your endeavor
     
    #2 Tombukt2, Dec 22, 2023
  3. Spradilak

    Spradilak New Member

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    Thanks for your reply. I embarrassingly enough read all 130 pages of the individual module replacement thread trying to get all the information and data I could. I also searched HV battery leak on this forum and believe I read I should put a lead on the negative module terminal and another lead on the module casing to test for what you're saying correct?
     
    #3 Spradilak, Dec 22, 2023
  4. Spradilak

    Spradilak New Member

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    I also wanted to add to my original post a couple things I remembered putting before most of it got erased.

    The car has lived its entire life in South Carolina, mostly parked in the blazing hot sun, occasionally garaged when I don't have projects going on, it's also pretty humid here aswell.

    I'm currently doing the charge/discharge cycles..so far only one has finished. It's only charging to about 4500 mAh before I guess hitting delta v. As I have the cutoff set to 7500 mAh. The first 3 cycles on the only module finished(module 7) look like this D/C,D/C,D/C

    0/3115, 1913/3911, 2482/4293

    Progress, but I'm beginning to think it might just be near the end.
     
    #4 Spradilak, Dec 22, 2023
  5. dpower

    dpower Member

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    How did this work out for you?
     
    #5 dpower, Dec 31, 2023
  6. Spradilak

    Spradilak New Member

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    Actually just finished the charging discharging about an hour ago. Rearranging my spreadsheet to form blocks at the moment. I should have it back in the car tomorrow and I'll update. Ended up getting all the modules about 5000, mAh so that encouraging but well see
     
    #6 Spradilak, Dec 31, 2023
  7. Spradilak

    Spradilak New Member

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    It worked out well. I believe I replaced 4 modules in the end and went from 23% battery life to 75% according to the Dr prius life expectancy test.

    Overall I'm very happy with it other than breaking the orange service plug and having to get another one. It took almost 2 weeks but was well worth it to me.
     
    #7 Spradilak, Jan 2, 2024
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