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How to remove Hybrid battery quickly and easily

Discussion in 'Gen 2 Prius Technical Discussion' started by 3prongpaul, Aug 20, 2013.

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  1. 3prongpaul

    3prongpaul Hybrid Shop Owner, worked on 100's of Prius's

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    Here's a video of us removing a Gen2 traction battery in about 10 minutes.
    (We cheated a bit and used multiple lithium powered impact drivers)

    Hand ratchets would take significantly longer. Apologies in advance for the bad audio.


     
    #1 3prongpaul, Aug 20, 2013
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  2. koolingit

    koolingit Member

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    I loved it! Now you've got to do one showing the installation. In the meantime, I'll be watching this one twenty or thirty times!
     
    #2 koolingit, Aug 20, 2013
  3. 3prongpaul

    3prongpaul Hybrid Shop Owner, worked on 100's of Prius's

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    Just watch it backwards for install procedure!
     
    #3 3prongpaul, Aug 20, 2013
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  4. koolingit

    koolingit Member

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    Seriously, I was wondering about the bolts. It looked like everything was 10mm but were they all the same size and thread pitch and length? I noticed you pointed out a few were black but were all the rest really the same size?
     
    #4 koolingit, Aug 20, 2013
  5. 3prongpaul

    3prongpaul Hybrid Shop Owner, worked on 100's of Prius's

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    There's a bunch of different fasteners, two 8mm nuts hold the orange HV cables to the black relays, plenty of 10 & 12mm bolts/nuts. The seat-backs are 14mm, so you need sockets for 8,10,12,14mm. Pliers to remove plastic barbs are helpful. If you view the video on Youtube directly my comments explain a bit more.

    If doing it your first time you could store each type of fastener in a muffin tin or take photos as you go.
    I've done it so many times I know which fasteners go where from memory.
     
    #5 3prongpaul, Aug 20, 2013
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  6. bisco

    bisco cookie crumbler

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    well done, thank you!(y)
     
    #6 bisco, Aug 20, 2013
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  7. Flying White Dutchman

    Flying White Dutchman Senior Member

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    Great video
    nice so see it compleet in 1 video

    --

    if anyone wants to see a relay replacement
    here is a old video



    or speeded up
     
    #7 Flying White Dutchman, Aug 21, 2013
  8. 3prongpaul

    3prongpaul Hybrid Shop Owner, worked on 100's of Prius's

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    I've never seen a main relay fail on a stock Prius. Do you think yours failed because of the PHEV system? The main relays are not designed to cycle with an active load.
     
    #8 3prongpaul, Aug 21, 2013
  9. Flying White Dutchman

    Flying White Dutchman Senior Member

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    yes that was the cause of it!
    human error and no patience.:)
    but no problem have some laying around ;-)
     
    #9 Flying White Dutchman, Aug 22, 2013
  10. 2009Prius

    2009Prius A Wimpy DIYer

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    Where can I get the big pliers-like removal tool shown in the video? Thanks!
     
    #10 2009Prius, Aug 22, 2013
  11. 3prongpaul

    3prongpaul Hybrid Shop Owner, worked on 100's of Prius's

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    #11 3prongpaul, Aug 22, 2013
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  12. jdenenberg

    jdenenberg EE Professor

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    A high voltage (300v), high current diode across the contacts (reverse biased so normally no current) would protect the contacts from inductive kicks. Slight chance of diode leakage causing problems when the Prius is off.

    JeffD
     
    #12 jdenenberg, Aug 22, 2013
  13. Sheepdog

    Sheepdog C'Mere Sheepie!

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    wow.mad respect. I bet you could remove and replace my aux battery while asleep and eating a sandwich! Thats on my mind as I need to do this next week! (the aux battery NOT what you did!)
     
    #13 Sheepdog, Aug 31, 2013
  14. Beachbummm

    Beachbummm Senior Member

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    LOL I thought I was doing good at 30 mins as a first timer with no power tools.....of course I forgot to push the handle down on the safty plug after I installing it and went over everything else 3 times but 20 mins later it was back running..
     
    #14 Beachbummm, Sep 25, 2013
  15. TonyPSchaefer

    TonyPSchaefer Your Friendly Moderator
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    I get the feeling you've done this before. Like, a few dozen times.
    Well done, Paul. Thanks for posting.
     
    #15 TonyPSchaefer, Sep 25, 2013
  16. ericbecky

    ericbecky Hybrid Battery Hero

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    Missed this post before.
    I've seen and worked with Paul before.
    The man is a machine. Knows every bolt and size without even looking.

    We should have a competition sometime to see who can do it the fastest. :)
     
    #16 ericbecky, Oct 12, 2013
  17. Gambitsource

    Gambitsource New Member

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    Hello everyone. This was a very helpful thread in getting the battery out of my 2007 Prius. I replaced 2 modules and charged 3 modules with power cycles. Next, after putting the HV battery back in and getting the car started I am back to square one with the power drain. I show 16.3-16.5 V per Cell on Torque Pro and when driving it I will come to a stop with my foot on the brake and I see the power draining slowing from the Hybrid battery. I wonder if I need to replace the whole battery... any thoughts?
     
    #17 Gambitsource, Nov 16, 2019
  18. Tim Jones

    Tim Jones Senior Member

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    priusbat4.jpg
    YES...............
     
    #18 Tim Jones, Nov 16, 2019
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  19. bruthajess

    bruthajess Junior Member

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    Paul, just wanted to give you props for a great video! It was super resource as I replaced my hybrid battery this morning!
     
    #19 bruthajess, Nov 16, 2019
  20. Gambitsource

    Gambitsource New Member

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    Not even the right battery man. Mine is 2007....
     
    #20 Gambitsource, Nov 16, 2019
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