Pulling the trigger on Cylindrical Cells

I am the 3rd owner of a 2008 Touring. Purchased in June of 2018, the Red Triangle made an appearance 2 weeks ago. Car is at 160K miles.

The 'pack' had been steadily showing weakened state, rapidly jumping from pink bars to green bars in a matter of a couple minutes. I had considered, then rejected, the Hybrid automotive charging system. Dr. Prius has been indicating 2 bad cells for some time, but dealing with the hybrid battery always gives me pause. I'm not a spring chicken anymore, so acrobatics under the hatch is not something I have the tools, diagnostics, nor the physique to waste.

If I am going to do it, it will be this one time. After chatting with 2k1Toaster, and reviewing the step-by-step Instructions for the Cylindrical cells, I purchased the Gen 2 Kit today. I'll share any challenges, or injuries that occur along the way. Take care, everyone.

 

I wouldn't mind recycling the cells, but is something I've never done. I'm wondering what tools/charger I'd need to recondition these Toyota batteries.

 

Weather Delay in shipping. Also had my 2nd Red Triangle, so this really is coming down to the wire, so to speak.

 

Box was delivered today. Hopefully will get the replacement going Wednesday.

 

As I'm going through the checklist for removing the traction battery, I get to page 22. This is the page just before you remove the high voltage cables from the battery and there is a stamped metal plate missing.
According to this documentation, one is supposed to be careful not to deform the plate (because it can cause fault codes). But what happens if the plate is not even there? My car wasn't throwing any codes prior to the battery dying, so I'm hoping this doesn't become an issue as the new cylinder cells are installed.

I have to say, the more I get into this vehicle the more I am disappointed in the guy who sold it to me. Missing snaps, missing plates, missing screws. It's no wonder the back rattles is it goes down a country road

 

Finally wrapped up. Took my time and double and triple checked all the connections. Car started up normally, with no error codes, and apparently that missing little plate that causes faults so far it has cnot created a fault

So far so good.

Considering the issues I've had with having to manually control the cooling fan, I'm curious if the new batteries, with the new placement of sensors on top, will allow the car to control the fan instead of having to use hybrid assistant all the time.

 

There isnt one. I wasn't prepared for specialized pieces. This is the first time I have gotten this far into the car since I bought it. The only thing over the top of the high voltage insulation is the case cover.

I didn't realize just how many times the previous owner stole from Peter to pay Paul. Every preformed piece of sheet metal is missing a bolt. Every interior panel has broken snaps. I discovered that I had a working hatch light because the previous owner never reconnected it.

 

There was one part of the NewPriusBatteries instructions that I had to re-read several times.

When changing to the cylinder batteries, you're discarding your OEM harness for the custom built one. The OEM harness connects near the bottom of the case. I wanted to submit this picture so that anyone considering the change could know exactly where the original harness terminates, and what it looks like. There are a couple of other white connectors located above this one, A small, long-stemmed screwdriver can press their locking pins to release them. On the orange connector, I wasn't familiar with that type of zip tie to know if could be released, so I cut it. .Lastly, notice the raised ridges on the compression plate. These are the perfect width to secure the extra length you will have on the new harness. Just tuck the excess wire into the space between ridges, and it will hold firm.

 

I would like to Thank 2k1Toaster for his excellent customer support. He quickly replied to my questions and concerns, and offered suggestions on the procedure. Everything was packaged and double-boxed expertly. Even UPS rolling the package off of the back of their truck couldn't hurt the contents! All the bricks were within a tenth of a volt to each other (15.8V to 15.9V).