generation 1 prius with gen 2 modules

ok so some of you know my HV battery on my 01 prius is on its way out, originally there was 1 bad module, but since i load checked all the modules i found another 2 that are bad.

heres my dilemma, using two 04-09 prius to rebuild a 01 prius pack, or buying modules whenever this problem comes up.

to me it seems that I would have to get new NHW11 modules everytime i get this problem, which i think would happen again, for peace of mind, im considering buying two 04-09 prius batteries. But will the same problems occur on the new prius battery?

Also if anyone knows an alternative module that would work, providing the proper 7.2-7.8 volt and correct capacity let me know.

 

Alright ill post pics, im gonna locate a deal on these batteries, if i can get two packs for 600 that would be great, i found a couple junkyards selling the packs for 400.

 

Great news, i got my hands on two 05 prius batteries for 500 dollars low mileage.


If this works i might put the 28 good modules from the 01 into the new prius battery case and paralelling it with my current 05 prius battery. Not sure how this would work yet.

 

i think i just had the deal of the year, i got a HV battery from a 07 prius with ~50k miles for 150 bucks, no bad modules!! i will post pictures tommorow, im just waiting on a second battery now.

 

Yup the deal replaced the two for 500, im going to try to sell the 07 battery ECU with the case to recoup my 150. Im also still looking for another battery, anything under 300 is a good deal for me. My plans are to pick the pack with lower voltage and charge the modules up individually to the higher voltage on the other pack. I recently purchased a NiMh charger so this should not be a problem.

Heres something interesting i found out on the 04-09 prius HV battery. The 01 prius had a service plug which in theory connected two halves of the battery ~ 140 volts on each half. The 04-09 prius has a 66 volt and a 144 volt "half" that is jumped by the service plug. I just found it interesting that its not exactly half as on the 01 prius.

Also something i noticed was the 04-09 Prius battery has almost no corossion on the copper plates.

Also pardon my word "jump" i just use it to describe the service plug connecting the two halves in series.

 

The gen 1 case is disassembled and a few modules are out, seems pretty easy once you loosen the sides, and the bar on top.

I didnt get time to take apart the gen 2 battery, today i finally got my 2nd battery ordered for 250 from a place in NY. SO i ended up paying 400 total for two HV batteries, which is a great deal in my opinion.

as far as i can see, I cant explain the reason behind the service plug and those two connections, im guessing, but not sure that the 144 volt is isolated from the ECU portion, while 66 volts would be, which means its a lot more safer to work on with 66 volts.

 

Success! finally I got around to swapping modules from a 05 and 07 prius HV battery.
The car drives like brand new, the gas mileage has improved vastly. I took it on a 15 mile run and averaged 55.8 mpg. Since i didnt have the battery cover on im not planning on taking it farther.


The only issue is the battery cover.
The 04-09 modules are larger, and im having trouble putting on the battery cover, so in order to fix this im thinking of cutting the original case and extend it 1 inch over the existing width, the sides of the case are pressing against the new modules.

Sorry for the large pictures, two of them are the two gen 2 batteries where the modules have been removed, one where all 28 is removed and another where only 10 have been removed. I have a lot of extra parts, including 38 gen 1 modules ( some are bad ), and 18 gen 2 modules and a gen 2 battery ECU.

Also something interesting to note, the 04-09 modules only have one screw that holds them to the case, versus two screws per module on the gen 1.

 

I dont think it would work if i used two 2g covers, reason is based on that big hole for the vent fan, i would have to fabricate that which = more work. I managed to get a few of the modules screws in. It initially didnt match up, until i tightened the hold down bars.

I didnt equalize the SOC levels since each of the modules from the batteries had 7.61 volts.

 

i think im gonna cut the cover lengthwise and add filler material to widen it maybe a half inch. OR retrofit the gen 2 case on the 01 prius case.

 

i was thinking of clamping the top of the case on two clamps and cutting straight down the middle with a reciprocating saw.