Gen II Prius Individual Battery Module Replacement

Is there a slimmed down FAQ on fixes for the failed traction battery? I've been reading this thread, but 83 pages is well beyond my limit.

I'm in an '04 with 277Kmi, been noticing degrading performance for a while now and just tripped the P0A80 code. I'm handy with tools, electricity and batteries, so no option is off the table. Looking to compare Time vs expense vs reliability of fix.

Jay W

 

If I had known what I now know, and were to do this again, I would have done one of the following:

1. Buy and install the Hybrid Automotive Prolong Reconditioning kit and see if that corrected the problem.

2. Buy replacement gen 2 modules from eBay and purchase the Hybrid Automotive Prolong Reconditioning kit to recondition the whole pack after replacing failed and/or weak modules to save time and money.

3. Find a cheap low mileage gen 3 pack and simply transfer all 28 modules from that pack to my gen 2 pack and maybe also recondition/balance it with the HA Prolong Reconditioning kit mentioned above.

I went with low mileage gen 3 cells from 2 different donor vehicles and car SoC acting normal finally and doesn't drop any blue bars upon acceleration except maybe one bar every once in a while. Car even after sitting overnight SoC doesn't discharge at all anymore, and car running better than when I bought it.

I have yet to purchase the HA kit to recondition/balance my pack, but I will do that in a couple weeks when I can afford to pick one up.

Prolong Battery Reconditioning Package – Hybrid Automotive

2004 - 2009 Toyota Prius Installation Instructions – Hybrid Automotive


Posted via the PriusChat mobile app.

 

Use this chart to find manufacturing date of modules so you know what you are purchasing while searching for modules on eBay.



Ask for mileage/serial numbers and/or ask sellers to take pictures of serial numbers if they can.

Posted via the PriusChat mobile app.

 

So from what I read today, just driving it and accepting the reduced performance isn't going to work for long. Apparently it will eventually go into a real limp mode?

Thanks, good reference. I have the equipment at home to hobble together a system to do the same thing the HA Prolong does. Besides, I'm a little leery about a product that brags about its high quality then presents a 2x4 mounted light bulb as part of its solution

Good reference on the cell dates. So is Ebay the preferred supplier of individual cells?

Luckly I have spare cars, this looks like its going to take a while. The options I've gathered are as such
1.) Dealer new replacement - More than the car can ever be worth.
2.) New Toyota supplied part, self install - Require conditioning? Old shelf stuff? - Thousands
3.) 3rd party replacement of "New" celled battery - $1500-$2000 - Quick turn around, some warrenty
4.) 3rd party replacement of "used" celled battery - $1000-$1500 - Quck turn around, minimal warrenty, if can be found.
5.) Self replacement of all new cells - $1000-$1500 - Slow turn around, no warranty, but should last years.
6.) Self replacement of select cells - Hundreds - Slow turn around, no warranty, but risky on next failure.
7.) Give car to charity - Feel Good.
8.) Sell privately for parts - +$1000
9.) Scrap yard - +$Dinner.

Anyone have additional info/opinions to add to this?

Thanks,

Jay W

 

Depends on what you wanna do with the car. At 277k other things might be ready to go like transaxle or inverter or something.

Last year I bought one gen 2 module for 50 bucks and did not do anything else like balancing or anything and got lucky and it lasted just shy of 1 year and 3 months.

When I opened the pack this year that module I bought was slightly weak and the two modules next to it had a thick white leakage spot in between them about the size of a silver dollar that was coming through the plastic film that covers the modules so I tossed them.. I guess this was electrolyte?

I put the other 25 up for sale on eBay for 25 bucks each, but I have no idea what condition they are in.

I assume they may be ok for awhile if reconditioned or used as an emergency replacement cell for real cheap.



Posted via the PriusChat mobile app.

 

And yeah.. thought the same thing about the light bulbs on a 2x4, so not so sure about that myself lol!

I guess it's just a cheaper alternative for people who can't afford this:

Prolong™ Intelligent Discharger – Hybrid Automotive


Posted via the PriusChat mobile app.

 

The real short cut method.

Replace the modules that have dropped to the 6.XX range.

Use your hobbied together charger to bring all the modules to full. At full the battery starts producing more heat and gas than charge. It's a good idea to have a fan blowing on pack. 650 mA is a safe charging rate.

Copy the HA tacky light bulb discharger. Run a couple of charge and discharge cycles.

Or you could just follow the instructions on the HA site using your own equipment.

There are no NEW 3rd party cells or modules. New comes from Toyota.

Brad

 

+ 1 to what stawbrad said. If you thought you could get a battery with new modules in it from reading a certain battery rebuilders site, you will notice they use the wording "new generation", whatever that means. What it doesn't mean is new modules.

That's exactly what it is.

 

3rd party NEW modules that fit the Prius are being produced.
You can purchase them.

But the rebuilders I know, stick with genuine Toyota modules.

 

Well, continuing to drive it didn't last long. Hit limp mode on the way home last night (luckily I work 2mi from home). I have the reader to reset, but from what I read, thats just a fix for a couple miles.

I kinda simplified my options
1.) Good warrenteed full replacement for $2000+ (+++ in some cases).
2.) Self unwarrentteed replacement for $1000 and a month+ down
3.) BandAid for $200 and a month+ down
4.) Give up

Considering other issues (smart key broke a long time ago, body pieces are falling off, etc) and other potential issues for a 275k car, #4 is looking real good. Wife has a '15 c and loving it, I see 80k '13 c on the market for less than $10K, would be nice to just upgrade. Really I was just hoping to max out the odometer. Had pipe dreams of driving the Alaskan Highway and selling it in Anchorage for air fare home.

I'll probably mull & morn for a little bit, then look for it for sale.

Jay W

 

How do you break a smart key?

Giving up is the easy way out. Depending on whether or not the HV battery can be repaired at low cost ( a module or two) will make it possible for you to sell it. Lately, used car prices have been insane . Virtually any car that runs and drives acceptably is selling for $1000+ even if it's beat to s***.

 

The older keys weren't as robust as the newer ones. The rubber wore away (just from being in pockets, we didn't need to push buttons), which I think let debris in to short and burn batteries then eventually no RF at all. One of them fell in a cooler of water too, came back a month later, but is now dead again. I have to insert them in the dash, but worse I have to use the emergency key to (un)lock the door every time.
"The easy way out" is what I'm looking for ;-). I could probably part it out for as much as I could sell as a POS runner.

Jay W

 

I doubt that. Your engine and transaxle are near end of life. The HV battery is practically dead. What other high ticket parts are left to sell that other Prius owners would want to buy?

Let us know what you decided to do when you do and what you got out of it.

 

We agree that the light bulb discharger solution is kind of lame, but it sure is a cheap way to discharge the entire battery quickly and effectively.

We are working on a replacement product that will be fully self contained and eliminate the need for light bulbs, as well as have some very nice functionality enhancements. It should be available to order before the end of 2016. Once the new product is out we will be discontinuing the light-bulb dischargers.

 

Will new version add to the price you think?

Can you give me some kinda rough answer on the question I asked on eBay?

I need to make my decision here soon what version I should buy since I mixed 58k modules with presumably 4k ones instead of getting all from same car I don't know how far off capacities might be.

How long before a cell would get destroyed and how far off would they need to be for this to occur?

What would any of you guys do?

Standard HA version, Reconditioning version or just keep driving it?

Car is working better than I have ever seen with super stable SoC in all scenarios except going drive-thru with headlights on.

Do you have any coupon discount codes floating around on the net?



Posted via the PriusChat mobile app.

 

You can get keys on eBay and program them yourself.

If I were you I'd open pack and replace all modules with newer ones from a much lower mileage Prius, recondition it, then keep it a little longer or sell it for maybe $2000 - $3000?



Posted via the PriusChat mobile app.

 

Sent you a note on eBay. We are still working on the final price of the new discharger, but it will be more expensive. Adding complexity in parts and requiring more assembly labor will definitely drive up the cost to the end user. Hopefully it won't make the offering too expensive for most people. We're hoping to keep it under $100 so that it is not too much more than the clunky light bulb setup, but it is really hard to say at this point.

 

K, just curious... thanks!

Posted via the PriusChat mobile app.

 

Hello everyone-
Started my rebuild using this thread nearly s month ago. Finished balancing recently and reassembled the car. Couple questions for everyone.
1. When will I know if my car is fixed and back to normal condition?
2. I have drove 16 miles after resetting the check engine light and red triangle, if and when is enough miles they will turn on?


I cleared the code because after I plugged in the hybrid battery and reconnected the 12v- the check engine and triangle came on when I first attempted to start the car up. When plugged in the reader it gave no error codes.....So I cleared it and it now runs fine. Battery recharge, supports engine etc. and got 53mpg driving around my hilly neighborhood. Thoughts? Should I have had to clear any codes aftter plugging everything back in?

 

Steve Keith bought a handful of those from China. They do not have two connections between each cell that the Toyota modules do. This is how the Gen I modules were made. That alone makes them not worth considering.

Brad