This is the 2nd Falcon Hybrid Solutions battery I have come across dead at an auction. Here are some pictures. I posted here (#23) a while back about the first one: Battery replacement, brand new battery pack from dealership questions | Page 2 | PriusChat This one has a different scoring system and has regular modules, B2 's and B3 modules. I usually see B2's in 2007 and up gen2 Prius and Camry's and B3's in a brand new Toyota pack. I believe that is also what is used in gen3 Prius. I will post a little more as I dissect it and I will try to research the history.
Were you ever able to find out more about what's causing so many of these Falcon batteries to fail? I'm also wondering why redbarron had to wait MONTHS and go through hell to finally get his money back. It makes me wonder if Falcon finally agreed to refund him in exchange for a non-disclosure agreement.
It is just the nature of a rebuilt battery. You are taking components from older failed batteries and re-assembling them. When it is all said and done you have a hodge podge of components from two or more old batteries that have already failed once. It is just a matter of time before another cell fails. I have stopped re-building batteries because it is a short term fix. If you are doing it yourself and are only investing $25-$35 for a used cell(module) and a weekend of your time it's not a bad way to go but a newer used battery that has never failed or new is the better use of money. I wouldn't recommend purchasing a rebuilt/re-manufactured battery from anybody. The best bang for the buck that I have found is buying a used 2012-2015 battery from a salvage yard and move all of the modules to your case. Then return your old modules as the core. You can typically find used 2012-205 packs for the same price range as the 2004-2009 packs and they will last much longer. Age (in years) is a much more important factor than mileage in hybrid batteries. There are no moving parts in a battery.