Snapped a post on hybrid battery cell.

Discussion in 'Gen 2 Prius Care, Maintenance and Troubleshooting' started by oneofmanysons27, Mar 2, 2016.

  1. oneofmanysons27

    oneofmanysons27 New Member

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    I screwed this up really good.

    I have been cleaning the copper connectors in my hybrid battery, they were pretty corroded. Anyways, the bolts were too, so I figured I'd just replace them. Well all ace hardware had was lock nuts.

    So I go to put the lock nut on and I figure I get to the plastic on the nut because it stops moving, but still has some play. So I keep torquing it down. Snap. I break the post off one of the hybrid cells.

    I'm up a tree. 20 miles from my house at ace hardware and no spare cells. Is there anyway to replace or fix this tonget me mobile again without having to order a new cell?

    I feel like an idiot. Thanks guys.
     
    #1 oneofmanysons27, Mar 2, 2016
  2. ChapmanF

    ChapmanF Senior Member

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    Nothing simple that I can think of ... don't try opening up the case to replace the post, it'll just be a mess, and potassium hydroxide is a skin-eating mess.

    Find a module on eBay or from someone nearby, order it from your phone, borrow or rent a ride until it shows up?

    And just for everybody else following along at home ... working on the battery module terminals? Look up the tightening torque and set your torque wrench accordingly. There's very little margin for error. Too low will be electrically dangerous, too high ... snap.

    -Chap
     
    #2 ChapmanF, Mar 2, 2016
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  3. exstudent

    exstudent Senior Member

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    #3 exstudent, Mar 2, 2016
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  4. ericbecky

    ericbecky Hybrid Battery Hero

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    If I truly had to McCarver something I suppose I might try soldering. Or maybe clamping a wire in place. Is old only do this in an extreme emergency.

    A better idea would be to call a friend and borrow/rent a car until you can get a replacement module.
     
    #4 ericbecky, Mar 2, 2016
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  5. bisco

    bisco cookie crumbler

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    macgyver?:p
     
    #5 bisco, Mar 2, 2016
  6. oneofmanysons27

    oneofmanysons27 New Member

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    Soldering sounds like the only idea to get out back on the road ASAP. Problem is all the solder will just run off. I'll need to flip the battery on its side..

    When I get to putting a new cell in, Is there anyway around having to rebalance the cell? Can I get away with just popping a new one in.

    I cussed like a sailor when I snapped that post.
     
    #6 oneofmanysons27, Mar 2, 2016
    Last edited by a moderator: Mar 3, 2016
  7. exstudent

    exstudent Senior Member

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    It will work for a very short period of time: minutes, hours, day(s).

    Your HV pack consist of 28 modules. Each module consists of 6 cells.
     
    #7 exstudent, Mar 3, 2016
  8. ericbecky

    ericbecky Hybrid Battery Hero

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    What I mentioned would be a very unsafe. It would have no guarantee of working.
    I can't imagine a time I would ever do it.
    But it is an interesting experiment. I'd make sure to wear safety equipment like eye protection in case things go awry.

    (McCarver? Ha, ha. Silly autocorrect! Of course I meant MacGyver.)
     
    #8 ericbecky, Mar 3, 2016
  9. oneofmanysons27

    oneofmanysons27 New Member

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    Hey guys, here's one for you.
    To those following my other thread on the broken off battery cell post; I replaced the cell, but now driving around my Prius will seemingly randomly die..

    I noticed a trend that it would happen when getting to full green bars, or hitting a bump...

    I checked and rechecked all my connections, nothing. Then a friend suggested I wiggle the orange safety plug. Bingo! Relay clicked like crazy, car died...

    Any ideas? Plug or female part?
     
    #9 oneofmanysons27, Mar 3, 2016
  10. oneofmanysons27

    oneofmanysons27 New Member

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    I'm not sure what's going on. Thought it might be the relay, but I unmounted it so it's floating on wires above the battery, still triggers it to tap the sheet metal or the plug... Hmm...
     
    #10 oneofmanysons27, Mar 3, 2016
  11. oneofmanysons27

    oneofmanysons27 New Member

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    So I reseated everything and checked the ground and the problem has gone away. But a new one exists now. Any acceleration is choppy, like a toddler is flopping a light switch, on, off, on, off. And my battery/mpg monitor is definitely not working correctly.

    Problem is significantly less if i run the car in B instead of D.
     
    #11 oneofmanysons27, Mar 3, 2016
  12. dolj

    dolj Senior Member

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    At a guess I'd say the "new" module is significantly different to the other 27.

    Given that in "B" it will put lower current into the HV battery than in "D", but not sure whether it affect the current draw on acceleration. I'm thinking it doesn't.


    PS, did you make sure the safety interlock was pushed firmly down after flipping it up 90°?
     
    #12 dolj, Mar 4, 2016
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