P0A80 2005 Prius

It's been my experience that module #1 and module #28 (aka Block #1 & #14) are consistently not as healthy as the other modules in a healthy pack. I've often debated with friends if we should simply always replace module #1 and #28 when replacing a pack's first bad module. Our theory is that the very first cell on both ends of the pack is where the most extreme loads first come into and out of the pack...

And seeing as I've seen super brief peak loads as high as 148 amps via Dr. Prius app, those first and last cells in a series of 168 cells may be more likely to experience damage from peak voltage events that the 120amp fuse didn't blow out on because the peak amperage event was super brief.

As for replacing additional modules, the real question is how thorough do you want to be?

--Load testing each module once the pack is out will help you find bad modules....

--Charging all modules up to max charge and then waiting a few days will point out modules that self-discharge faster than others.

--Reconditioning modules by discharging each module in a race with other modules will show you ones that haven't failed but are likely the next ones to fail.

Putting all this data on a spreadsheet for future studying is essential too. More info once you clarify how much work you want to do.