TMR-JWAP, I'm going to repack my gen 2 with gen 4 mods tomorrow. From what I can tell, it looks like I might be able to swap the entire pack of mods stripped down with end caps still attached. There are a few differences to work around, so even if it could be done, I guess it wouldn't be worth it?? Is there a market for a good second hand gen 4 hybrid battery case I won't be using? All like new from 2017 Prius, 13,000 miles.
The issues you'll need to work around are: the side clamps on the gen 2 are smooth on top except for the bolt bosses. The gen 3 (and gen 4 iirc) have extra tabs on top for cables. I've used gen 3 clamps in my gen 2 builds because they have better reinforcement, but I machine off the extra tabs so the black plastic trim piece fits correctly. the gen 2 clamping bar set has a small metal tab at the non-ecu end for mounting a temperature sensor. No big deal, since it's your battery, you can zip tie it if desired. Personally, I would put the new modules into the old clamp set. Just make sure you note the orientation of the + and - and make sure the gen 4s are installed exactly like the original gen 2 modules. It's very easy as they interlock together. No significant market for gen 4 cases, that I know of.
okay that's scary - I just rebuilt my hybrid battery, but I'm too frustrated to figure out how to post a pic and not lose everything I typed twice. Anyway thanks to all here for sharing your experiences. My results of going from a 14 y/o hybrid battery to 2017 mods is looking real good. Up and running and the first trip of 29 miles is showing about 10 more mpg in mixed normal driving I'm blessed and very grateful.
I would like to note here that I'm fully on board with TMR-JWAP with using G4 mods to repopulate earlier Gen battery packs. As I said in previous post I had chosen this option before in a G1 (using latest G2 mods) 7 1/2 years ago. I will add: having/taking time to research, weigh the costs & risks for the different options, finding salvage mods that are late model and legit, trusting that God has given you abilities, having adequate tools will not be the case for everybody. So, I'm saying if I had been within striking distance of somebody like TMR-JWAP, I would rather have him do this work for me, save me time and would learn from him.
According to Toyota they used a higher grade of Nickel in the Gen 4 cells too. Perhaps longer lasting?
If you start another one I’d be really interested. I’m in central jersey but my parents are in Taylor’s SC. iPhone ?
This looks like a heck of a lot of time and work. Don't know how there's any money in doing it for $1600. But it certainly is admirable. Alternatively, you Gen 2 and later owners can get those new stock round modules to rebuild your batteries. Same price. Equally good deal, I think.
Only if you are referring to @2k1Toaster kit of new cells. There is another vendor (CEBA?) using the same mounting with inferior cells. The link for the good ones is in my signature.
Like what? 2k1Toaster's kit or a gen 2 battery with gen 4 cells? If the former, check with @2k1Toaster. If the latter, Todd at Home - Tampa Hybrids Inc. probably can fix you up. I don't think he'll ship, but it's a nice drive from your area.