I just rebuilt my Gen 2 hybrid battery and I crushed the temp sensor.

You can probably trade that part with a shop that buys new Toyota batteries. Every one they buy, they have to return a core with that part on it

 

I think you could use it

 

So what happens when you have a cold morning or a very hot afternoon and there's a 50+ degree difference between temperature indications?

Did you actually damage the sensor or just break the clip? Pretty hard to actually damage the sensor.
If just the clip then just use some rubber cement to mount it in place, or you can do what I've seen in a couple Dorman batteries and just let it lay in the bottom plenum.

My mistake, thought you were referencing just using a 10k resistor

 

Sometimes if it is just laying in the bottom plenum I see the temp difference between the different sensors make the Prius throw an error code.

 

If you prefer to have the correct one, just message me through the 'start a conversation' link and give me your address. I'm sure I can find a damaged harness in the shop and can cut one off with some lead on it. I can't provide same day delivery like amazon, but I can have it in the mail tomorrow.

 

here's a chart for the amazon thermistor. It looks to be fairly close........

 

well done! For some reason, I was expecting solder and heat shrink..................always forget about the handy/dandy splices. Showing my age I guess............

 

Getting ready to finally take this on; question: is the transistor-y-looking thing (see red arrow) part of the process (and how/where) or am I just splicing together the wires, as per the pictures in this thread?

 

That's a resistor. What's the rating on it.

 

Hey everybody
New to the forum
I was just wondering also to this thread
as i have the exact same problem at the end of my lower temperature wires under the traction battery (the thermistor?)on my06 prius
I noticed the question wasnt answered about the resistor that comes with the repair kit bought thru amazon
Do i need to install the resistor as well?
Any help would be greatly appreciated
Thanks greg

 

I have a similar problem, the sensor broke off with no wire left on it to reconnect. Can I just search for 3950 thermistor on Amazon? I found several, will any of them work?
I appreciate any direction you can give.

 

Rather than replace the half dozen cells in my 2006 Prius HV battery, I decided to replace all the cells from a good battery out of a 2011 Prius. When removing the cells from mu 2006 battery I discovered that the middle 1 of 3 temperature sensors had melted and had damaged the cell next to it. The other temp sensors clipped to cells 1 and 28 appear to be okay.

1) Is it normal for the middle temperature sensor to be inserted (jammed) between 2 cells (#14 and #15) rather than clipped to the bottom of a cell?
2) Are 2011 Prius temperature sensors compatible or the same as the 2006 Prius?

The car has been excellent since I purchased it in 2008 so I'd really like to keep it on the road.

Thanks,
Gerry

 

1....absolutely not normal. All three temp sensors should be clipped to the bottom of a module in the appropriate recess. There should also be 2 extra clips under there holding the wires in place. There should NEVER be one mashed between 2 modules. perhaps this was a previously rebuilt battery?

2....I'm not 100% certain whether the Gen 2 and Gen 3 thermistors share the same temperature characteristics or not. I do know the Gen 3s slip into the top of a module instead of clip onto the bottom. In that aspect, they are mechanically different and can't interchange due to their physical shape.

3..I'm still trying to wrap my head around this to understand how it could even happen...any photos? I discovered that the middle 1 of 3 temperature sensors had melted and had damaged the cell next to it.

 

Thanks for confirming. There were some different coloured lines marked on the cells that made me suspect that it had been rebuild. It worked extremely well for over 10 years and 400,000km so I'd like to keep on the road.

I have 4 clips and 2 sensors. The middle temp sensor melted and damaged cell #14 (now reads 226+ V). I plan to replace all of the cells with a good complete set in the exact same sequence as I'm removing from a 2011. Can you suggest where I can get replacement wiring and sensors?

I wonder if the Thermistor patch that Derekc spliced into place is still working.

 

Hi Joe:

Did you get a reply to your question, and have you tried splicing the Thermistor into you battery temperature sensor wiring? I have the same problem - my middle sensor melted so I need to splice in a new thermistor. Did the 3950 thermistor work? I'd appreciate any tips you can offer.

 

Hi Gerry, while on here searching for info on those sensors to help you out, I found your post. Talk soon , Steve W