Corroded HV Power Cable + More!

Discussion in 'Gen 3 Prius Care, Maintenance & Troubleshooting' started by alchemycarta, Mar 15, 2023.

  1. alchemycarta

    alchemycarta New Member

    Joined:
    Mar 15, 2023
    1
    0
    0
    Location:
    Portland
    Vehicle:
    2010 Prius
    Model:
    Three
    Hello all

    My 2010 Prius has 160,000 miles and pulled codes P3004, C1241, U0155, U0142.
    I knew it was the HV battery because it's age and went ahead and purchased a Nexcell Lithium replacement online.
    I'm doing the replacement and repairs myself as I'm more technical than mechanical and have more faith in me finishing this easily than if I were to replace the head gasket for example.

    However, while I was taking everything out to get to the battery I noticed a bit of water, just a couple of ounces, on both side compartments near the spare tire well. The compartment under the 12v battery was damp and had moisture and on the total opposite there was a small pool of maybe an ounce or two of water.
    I let it sit in the rain (after removing everything) and found the leaks are coming from behind my bumper.
    So that's that. I'll fix it after the main focus.

    Once I got the battery cover off I noticed a looooot of corrosion and some rust.
    Cleaning the bus bars and the nuts are no biggie, just time consuming. However, my worry are the HV battery cables and the aluminum sensor wires that fit over the bus bars.
    I know the battery chemical reaction is a base of 12PHso some boric or sulfuric acid will help along with a brush over from a 2500 sandpaper. (Don't do this to the nuts or it will damage the coating!!)

    So my question is, what's the best way to clean off the corrosion from the main HV power cable and the sensor wires on the opposite side without it traveling up into the wires and possibly causing more damage than intended? The (-) HV cable isn't nearly as shiny and copper colored as the (+) cable for example. (See photos)
    I posted photos with the error codes, battery block monitor, and photos of everything else I've mentioned. Hopefully that should be enough to display/expose my worries and give clarification to you.

    Tl;Dr - What's the best way to clean corrosion sugar from the HV power cable and the bus bar sensor cables without damaging them?

    Thanks so much
    Screenshot_2023-03-01-13-01-44-61_1c4cade50911c4021d022fd7fc21ca47.jpg IMG_20230315_184345.jpg Screenshot_2023-03-01-12-34-31-89_4c9d9310924d052fe4000da8e14e845e.jpg IMG_20230315_184517.jpg IMG_20230315_184625.jpg IMG_20230315_183916.jpg IMG_20230315_183931.jpg IMG_20230315_184252.jpg IMG_20230315_184301.jpg IMG_20230315_184315.jpg IMG_20230315_140435.jpg IMG_20230315_140507.jpg IMG_20230315_140534.jpg IMG_20230315_141856.jpg IMG_20230315_141906.jpg
     

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  2. K Hughes

    K Hughes Junior Member

    Joined:
    Aug 24, 2021
    5
    2
    0
    Location:
    36580
    Vehicle:
    2006 Prius
    Model:
    N/A
    vinegar and salt, then wire wheel if any corrosion is still on the connections. I coat my connecters with a little bit of connective grease (not dielectric grease) to reduce corrosion in the future