$5,000 battery replacement quote from dealer....

Thanks @SFO I'm on it... Will post a follow up summary and hopefully we can all get a good laugh at how low my repair price was compared to the stealership price.

 

Not sure where to find the best price, but these all look less expensive :

https://www.toyotapartsdeal.com/oem/toyota~wire~frame~no~2~82165-47040.html

Wire Frame No.2 - Toyota (82165-47040) | Toyota Parts

Wire Frame No.2 - Toyota (82165-47040) | TRDShop.com

amazon.com/Toyota-82165-47040-Frame-Wire/dp/B01FCX1H88

 

Not sure about those links... Wire frame? That doesn't make sense? Based on wacky sensor readings I'm thinking corrosion damage to wires in voltage sensing harness and best price on a new one of those on ebay is this NEW TOYOTA PRIUS BATTERY WIRE SENSING HARNESS 82165-47040 OEM 04 05 06 07 08 09 | eBay

Please clarify if I've misunderstood your terminology/part?

 

Camper,

The wire frame #2 I posted a link to is the sensor harness. It has all the sensor tabs, wires, ecu plug and the busbars already assembled in the orange plastic. It's a complete harness, (you'll love it and never go back to used ones) with the exception it does not have the heavy orange long and short cables that attach to the main relays.. Those are separate items to order.

The ebay listing is exactly what we're talking about. Look at the label on the plastic bag, it says wire frame #2. The ebay listing is a bit more expensive, but you may get it quicker.

 

Nope, that's not me. You'll be good to go if you have that harness on standby. You'll just need to add the long and short heavy orange cables to it. It has everything else already.

I've only done one battery locally, and that was for a co-worker friend. I built a battery using some 2011 modules, she and her husband drove over in two cars and left hers at my house. They ran some errands for a couple hours and returned with a check in hand. All the others I've done have been 80+ miles away. I ask my self all the time why it is that no one in Columbia can have a bad battery. Maybe I need to throw an ad on Craigs List.

 

If you aren't in a hurry for that part, $51.74 at Camelback Toyota in Phoenix, and just pay for shipping; no tax since you are not in AZ. You will have to manually enter the part number (82165-47040). If you add some maintenance items (oil filters, drain plug washers, water pump, belt, inverter pump, etc) to hit $150, free shipping. Maybe ask another friend/coworker w/ any Toyota, to buy such items when you place your order? You both win.

 

He could try this site also to see how much the local dealers are charging.

Toyota Parts Center Online | Genuine Toyota Parts & Accessories

You would still have to pay sales tax but you can select pickup at counter to save on shipping.

 

Those results appeared after searching for "82165-47040". The linked text/terminology was from each website.

Those linked parts could be something else, though seems unlikely if the PN is the same.

 

Yes, but is that just the frame that holds the wires, or does it come with all the wires too? Seeing as it's a part sold by a dealership, I'm guessing it's just the plastic frame and not the wires or bus bars...

 

Have faith young grasshopper. Wire frame #2 has all that..the orange plastic frame, shiny new busbars and beautiful new sensor wires and ecu plug. Already assembled and ready to go...just add heavy orange power cables.

 

Thanks for clarification... that's a great price in that case... but the graphic is the opposite of that... It's not that color and there's no sign of wires.

 

If anyone here knows if it’s the correct part I would put my money on TMR-JWAP. The guy rebuilds battery’s for fun (and some profit).

 

Final Summary / Report on this Prius:

As luck would have it a week ago Saturday I installed my first brand new battery pack for @cpquit and being my first experience I didn't realize new packs come with brand new wire frame, bus bars, nuts and covers already mounted to the chassis, which saved me 45mins of install work and we didn't need those parts he bought for his job, so I got the new wire frame and new nuts as part of payment for the 2 hour install, which I was able to use on this car.

After a test drive we were both pleased with how strong a brand new pack is and I then was off across the lake to Seattle to pull this car's battery pack and put in my loaner pack. And because dealer charged $400 just to take the pack out and look at it, I found a certain amount of justice in only charging that same amount do all the work, including cost of parts. Best part was I had all the parts on hand and ready to go, which is a rare and beautiful thing.

Then, last Monday I reassembled the pack on a spare used chassis because too much of the old one, electronics included was trashed. So everything was replaced except the modules. Then I put the pack in my car and charged and balanced with Prolong charger and returned to Seattle this past Saturday after 150 miles or so on rebuilt pack with no issues.

The voltage and load test numbers on pack looked really good compared to most packs I've worked on... Previous rebuild on this pack replaced 3 modules (#4, #5, #6) from a 2008 pack and they were really well matched with rest of pack and need for reconditioning modules was minor enough at the moment that I was able to cut costs that way and will revisit that part of the job once owner decides on new, or newer pack, or more search and replace for bad modules in this one..

As for whoever did the rest of the work beyond the modules, they had very little mechanical skill and there was evidence of a great deal of frustration for all parties involved. Allegedly the previous owner had to pull the pack 3 times and send it to California. I'm assuming some kind of warranty work. The pack was covered in lots of greasy grime, like it spent a long time sitting in a really dirty auto shop without its metal cover, which is probably when they lost tracks of many of the pack's parts. Anyways, here's the translation of dealership notes and further below are links to photos:

"Two Blocks would go from 0 to 14 volts" means corrosion in voltage sensing harness caused this. Same with "open circuit at bus bar wire block 2-3"

"A heavy leak on one side of the battery" was not a leak, but a liquid wrench type product used in a failed attempt to remove stripped nut from terminal.

"Heavy Corrosion on the nuts and bus bars" is actually a normal amount of corrosion, but it should of been dealt with by person rebuilding the battery pack.

"Main Relay no. 3 also has heavy corrosion build up." is true and probably wasn't an issue but mounted the battery pack on a different used chassis in much better condition and with no corrosion rather than test it.

"All bus bar covers are missing" means 3 of the 4 black plastic covers to insulate the bus bars and nuts were misplaced by person rebuilding the pack. Probably because it appears the pack sat disassembled in a really dirty mechanics shop for a long time, likely due to the stripped nut they were never able to remove.

"Recommend... Battery carrier bracket and grommet #1" makes no sense to me?

"Recommend... Hybrid Battery Computer Assembly" means the voltage sensing wires shorted out inside the computer plug.
-----------------

Brand new nuts and wiring harness (aka: wire frame): https://photos.app.goo.gl/fTgcoVWkXy9pZBWP9

Brute force bus bar plastic damage from previous repair people: https://photos.app.goo.gl/xQXL6SZpcWXrRbTj9

Stripped nut that previous repair people failed on: https://photos.app.goo.gl/UQAc4EEHLSa4Ud1U6

Stripped nut successfully removed: https://photos.app.goo.gl/BydaxBWFZsVp63Ut9

Corrosion on relay #3: https://photos.app.goo.gl/5eWvZgJMkt8v5J9H7

Corrosion caused short-circuit on battery computer plug: https://photos.app.goo.gl/sp4pGeEp2cbJ8smi9

Close up of battery computer socket: https://photos.app.goo.gl/vffVkfrqXy45bj8q7

Corrosion inside of computer almost reached circuit board before it failed: https://photos.app.goo.gl/w6CsKcgu7qETPiae6

 

Works. Great post!

 

Hi every one,
Been a long time lurker here. Lot of helpful posts and even more helpful members in the forum. Few weeks ago my HV battery failed (PA080) in my 06 Prius with 255K miles. I initially thought whether its worth to invest in new battery pack for such old and high mileage car. But the same pack can be transferred to others, should I decide to get Gen3 or even some trims within Gen4 I believe. Not that Gen 4 packs would require battery replacement so soon. Manufacturer date on new pack I bought from dealer indicated that it is built Mar-2019. So any car I move on to and is compatible with this pack I can make use of it. Besides I don't have other issues with my current car (Knock on wood).

I checked around the Toyota dealers in around Seattle/eastside. Toyota of Lake city gave me the best price ($1699) for the battery, Toyota of Bellevue didn't want to sell HV battery at all and Toyota of Kirkland, while has friendly staff couldn't match Lake city's price. Once I have the pack ready for the swap, I and @PriusCamper scheduled a Saturday for swap. He arrived and made the swap and explained the process throughout. Whole process took around couple of hours, including the fan cleaning, vacuuming around and doing everything at leisure pace, which I liked and wanted. Test drove after the swap, all went well. It's been a week now and is functioning as good as one can expect. So if you are in PNW area, I recommend contacting @PriusCamper, He is very knowledgeable with battery issues/troubleshooting.

Oh one more thing. When you go to pickup the battery from dealer, the packaging that contains new battery is huge. 4 Feet long, 2.2 Feet wide and 1.5 Feet tall I believe. So make sure it fits in whatever car you plan to carry it. I used wife's Crosstrek,rear seats folded, to bring it in. Core (old battery) should go in same packaging and I used prius (rear seats folded) to return. While there is no certain time frame (as they charge deposit while buying) dealer recommended to return within couple weeks.

 

Sorry about that Camper. I was under the impression you were just going to repair the battery. If I had recognized the plan was to go "new OEM", I could have saved you the hassles with the harness...

And,,,great write up. I just ran across a nearly identical "smoke release" on a 2012 Gen 1 HV battery I just disassembled. Was wondering why a 2012 factory replacement was being sold as a core...now I know.

 

What do you mean by "smoke release" ? And Toyota still builds brand new replacement packs for 2001-2003 Prius? I'm confused?

 

An old saying about electronics....they're all manufactured with a small amount of smoke inside them. They're no good anymore after their smoke gets released. Your plug and socket had the smoke released. The Gen 1 I recently disassembled had a very similar problem at the plug and socket. The associated pins in the socket were vaporized also.

I'm not 100% certain if Gen 1 batteries are still being made, but I know they were at least into 2015. A lot of people call them Gen 1.5
They're still manufactured exactly like the original Gen 1 modules, with the plastic sides instead of metal. The one I just disassembled had 2012 date code serial numbers and a 2012 date code sticker on the case.

They're easy to ID, since they have double the usual number of stickers on the exterior to cover other languages.

 

As a note, instantaneous voltage swings can be related to HV ECU problems. My my one burnt through the connector, it would swing from +14 to -14 volts. I am not sure of going between +14 and 0 is as serious. It may just be a loose voltage sense connector.

It might be worth having a spare ECU on hand just in case. And also opening up the current ECU to inspect for corrosion if everything seems good.

If the ECU is dead, it should enter some repository of 'dead HV ECUs from all generations of Prius', as with some work, these are going to be come repairable again, and they are running out over time! - please get the person to consider that, rather than landfill

 

Actually, I see you fixed it! Did you manage to use the old battery ECU, or just use a new one? As it looks pretty well corroded!