Gen 2 New OEM Toyota Hybrid Battery Replacment April 2023

You get the "main" steel case with all the modules, voltage & temperature sense harness, and busbars already installed. In separate bags are the high current cables, foam air seals (that fit around the cables), and some nuts for the cable connections to the modules.

You have to transfer the steel ecu end housing (has the ecu, current sensor, and contactors), install the high current cables (including the HV fuse connector) - torque the nuts to 48 inch-pounds (take pics of the original pack before disassembly - it helps with getting the cable routing correct).

As always, check the ecu pins at the orange connection for any corrosion before reinstalling it.

Fit the air baffles, vent tubes, and foam seals before putting the lid back on.

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Thanks, very helpful. A few more questions:

Other than the chunk transferred from the old battery, is there anything needed which does not come with the new battery? (I recall some reference to "single use nuts" (or maybe it was fasteners) in some other thread, and it wasn't clear if the poster had to go out and buy some or if they came in a bag with the new battery.

Is there a parts list inside the "coffin"? Helpful on the off chance that this particular battery is missing something.

Does either case have to come apart more than just taking the top off?

How long, roughly, would it take a first timer to "complete" the new pack by transferring the tray from the old one and install the other miscellaneous parts? (Don't include the time to remove and reinstall the battery, just the pure battery operations.)

I have a copy of the 2004 service manual somewhere. Which section describes battery replacement?

Finally a safety question. Does removing the orange connector disrupt the path along the modules in the battery, reducing the maximum voltage present from ~200V to half that or less? For instance, if after the plug is pulled and all the voltages are <40V gloves really aren't needed. Still need to be careful not to short anything live as the resulting flash can be eye damaging.

 

Well this is strange: the price if you just walk up to the counter or call is about $400 more, but they will honor the online price if you show them the page. Or just order it online and since it can't be shipped (from this dealer) just pick it up at the parts counter for the lower price when it comes in.

 

Found the copy of the manual (PDF has a date stamp in 2006). The relevant one seems to be section HB. Lots of descriptions in there, although none that I see which corresponds exactly to installing a G9510-47031. There is a tear down, and a rebuild, but not an "install new battery".

Anyway, on page HB-84 there is a diagram which shows some of the non-reusable parts. One of those is a cushion (squished foam rubber of some sort, so sure, not reusable) but the others are all flange nuts which were only torqued to 48 or 50 in-lb (as if a torque wrench is really accurate enough to make that distinction). So are they really saying that the flange nuts which are removed should not be reused??? I'm familiar with that for bolts which have been seriously torqued down, and so will have stretched, but 48 in-lb wouldn't normally distort a chunk of steel.

Side note, the dealer wants $1050 labor to install a G9510-47031, at 3 hours time. $350/hour, yikes!

 

Yes. Put the back seat down and the package can be placed far enough forward that the hatch will close.

46" x 26" x 20" (A pack is 34" x 16" x 7.5", so at least 5" of padding in every direction.)

90 pounds? The big bumps on the top and bottom covers are molded stiff plastic so they take up space but don't weigh much. My son and I had no problem lifting it off the cart and sliding it into the car. The weight was probably close to evenly divided and to me it felt like something on the order of 45 pounds. It would be awkward for a single person to lift because of how bulky it is.

 

Well here's a lesson learned, always open the case on the new battery before disassembling the car.

I did it in the other order, extracted the old battery from the car and set it down on the ground, opened its case. Pulled the new battery out of its huge box, opened the case and found this mess in the new one:


Note the stress marks in the orange plastic

Here are all the pieces just as they fell out when the case came off. The little hooks on the orange plastic are all snapped off so there's nothing to hold the black plastic on.


The dealer "kindly" offered to get the plastic pieces so that I could replace all these broken ones, but I told them no thank you, I would rather have a new battery which is intact on delivery. Basically I didn't trust that the battery wasn't damaged in some other hidden manner. So they ordered another one.

When we were driving this thing home in the Prius we kept hearing clinking noises when we went over bumps, but didn't give it much thought, figuring it was just something bumping in the back seat foot well, since everything from the trunk was stuffed in there. I now think it was the plastic pieces bouncing up and down within the metal case.

We are opening the next shipping container in the parking lot at the dealer and inspecting inside the case before we drive away. Couldn't have done that with the container inside the Prius, but since it will be in the bed of my son's F350 there's plenty of room to work this time.

 

That link is dead but when I go to that url and put in "G951047031" it says it's a radiator assembly. Please advise bc I need a new HV battery. Thanks

 

Our battery did not come anything like that My battery came to the Toyota dealer I ordered it online through the company to be shipped to Rick Hendrick Toyota in Apex North Carolina It came in a box that look like it was made for refrigerated shipping It was this big fiberglass looking two-piece container kind of look like one of those things on the side of the road that all the telecommunications stuff goes in and it was heavy too just the container empty was heavy and when he drug that thing out on the loading dock and they pulled the lid off of it the battery was sitting inside of this container with foam white styrofoam all the way around the whole metal battery case with no front end attached to it this is for a generation 2 I imagine in this case this battery could probably be dropped from waist high and not be damaged but I wouldn't swear to that there is no way that at the time I was picking this battery up I would be taking all the 10 mm screws off the battery case so I could look under the metal case but hey if this came in any other kind of container then maybe so I was quite impressed by this container they drug out onto the loading dock to take it out of and put it in my Prius they offered to help me pick up the battery and all that nonsense I told him just step aside get out of my way please don't touch anything and I pick that sucker up and set it on the top of the seat backs folded down and then I took my battery that was sitting on top of the battery running the car I had a battery all ready for my core and dropped it into that container and I literally dropped it from about 10 in in the case thump nothing happened and they drug the case off and said your core will be processed within 24 hours so on and so forth . And I drove off God I would hate to think something like this could even be in the mix but something that heavy shipped in just a box I wouldn't think that would work out I should have taken a picture of this thing when it was in its container It was pretty impressive. Plus the Toyota dealer could have turn around and said oh you left with it blah blah blah it's an electrical component and all of that but I guess the damage kind of speaks for itself that was seriously dropped or something those plastic things don't break like that when I disassemble the battery I peel that stuff apart You can sounds like plastic is clicking apart like the heavy plastic velcro kind of makes a ripping noise and then when I assemble the bus bars back into those orange strips spray everything mount them up to the studs screw them on stick the black caps on they click right on there no problem like they're supposed to be there seeing them broken like that kind of impressive looking because I can take some pairs of those things that I have out here and go out and wave them around in the air and smack them against things and they don't break so seeing them just falling apart inside of the case that's pretty pretty wild I have those orange strips and things laying under my shop I mean just tons of them I've stepped on them and walked over them before nothing no damage.

 

My best guess is that somebody dropped it on its side at the factory, looked around, saw that nobody had noticed, stuffed it and all the broken pieces into the shipping case anyway, sealed it up, and walked away whistling nonchalantly.

Anyway, it sure looked like it hit something pretty darn hard on that side, and for that reason it didn't seem prudent to gamble that there wasn't some sort of invisible internal damage in one or more of the modules.

 

No doubt I wouldn't gamble squat but yeah somebody somewhere did something for sure That's why I would think well maybe they didn't open the box they just had the whole box in the trunk that's the trick I guess or what I missed I didn't get to take the box with me The box that my battery was in at the Toyota dealership I had to put my battery in that container because it gets shipped back to God knows where so I guess I'll see when I order another battery which is going to be here in the near future how it comes I'm expecting it to come in the same big nice person case that I saw the first time I'll take pictures of it this go around It was pretty cool looking look like something body parts or something would be shipped into a hospital a little more stouter than that but you get the idea

 

For you folks that are finding the HV Battery on the dealer website could you post a link so that maybe I can see what I'm looking for?

I've check every dealership within 100 miles and the ones that actually do have a parts catalogue, none of them even list this battery. Most of the sites however I can only find a part request form. The 2 dealerships that I filled this form out for, I never got a response.

 

G9510-76012 - Drive Motor Battery Pack 2011-2017 Toyota | Longo Toyota Parts

Your observations are correct though, most of the dealerships do not let you look this part up through their web interfaces. To shop you will have to call each part department one at a time and ask for a price. I think the deposit is the same in all cases though.

 

I'm not understanding that if I know the part number here I can look up my battery right online and order it through Rick Hendrick have it sent to the Apex store and so on and so forth I'll have to go look again I guess but anyway this is the way you want to do it You want to order it online and pick it up at the store that you choose. Don't pay the dealer's parts department do everything online That's the way your deposit will be returned to right online to your credit card.

 

The link
In previous post is Gen3 battery and tray. Will not fit in gen2.0r metal tray is removed changed screwing up warranty.

 

Anyone have a link where I can order the G951047031 gen 2 prius battery? I can't find any official online sources other than the remanufacturers. I'm looking for OEM.

 

Also, I am in NW Michigan, if that helps point me to a reasonable dealership.

 

Just contact your nearest Toyota dealerships Parts Dept.

 

The dealers have different prices from each other (often).
The dealers may have a different online vs. at the counter price, with the former usually lower.
All the dealers can get an OEM battery for you.
They will all charge the same core fee.

I suggest making up a list of conveniently located dealers.
Then go to their web sites and see if you can get the battery prices through the "parts" link. It may not work at some dealers.
Then contact all the ones that remain by phone and get the price from the parts department directly.

Is NW Michigan the part next to Wisconsin? I think there is a forum member in that state who does pack replacements, but I don't recall who it is.

Edit: ericbecky

 

Does anyone know if a second gen Prius can carry the box or do I need to use my Ranger?

 

No issues fitting it in my Gen 2.