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Broke Hybrid Battery Service Plug off inside battery.

Discussion in 'Gen 2 Prius Care, Maintenance and Troubleshooting' started by Spradilak, Jan 1, 2024.

  1. Spradilak

    Spradilak New Member

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    So as the post says..I finally got done doing my reconditioning, everything was going amazingly well. I went to go out the service plug in. While I was lifting the totating the lever up I felt some resistance but continued to push anyways....and it broke.

    Now the remainder of the service plug is in the battery socket and the locking tab is laying in my backseat. How the hell do I get the rest of the plug out of the socket? No amount of moving side to side or up and down will break it loose..is there a tab somewhere that I'm missing that needs to be pressed in? I could really use some help here.

    Hopefully toyota stocks these and I can pick one up tomorrow..

     
    #1 Spradilak, Jan 1, 2024
  2. Spradilak

    Spradilak New Member

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    OK I guess I jumped the gun. I stuck a flathead in between the orange of the service plug and the black socket and slowly twisted it around the perimeter until it came out. I post this incase the same thing happens to someone in the future.

    If you feel any resistance when swinging the locking arm up DO NOT GO GORILLA ON IT. It will break..now I just need to find a replacement. Thanks.
     
    #2 Spradilak, Jan 1, 2024
    bisco likes this.
  3. PriusCamper

    PriusCamper Senior Member

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    Glad you didn't get yourself electrocuted! This is probably one of the most high risk problems you could have with an HV battery pack.

    Of course I'm sure you had insulated tools and high voltage safety gloves with fabric gloves over them, right? Lol... Not!
     
    #3 PriusCamper, Jan 1, 2024
    Spradilak likes this.
  4. Spradilak

    Spradilak New Member

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    I did in fact have insulated tools(only for the 8mm bus bar nuts)and 00 gloves for the assembly/dissambly process, however I didn't use the gloves to put the safety switch back in. But I did put them back on when I carefully pryed it out with the screwdriver. Not gonna like I was pretty nervous.

    My job is an offline reworker at the BMW manufacturing plant in SC, so I brought my insulated 00 gloves and 8mm home with me for Christmas break. :D

    I just hope that one of the dealerships near me has it in stock since my other vehicle is a 1990 Chevy silverado and that thing chugs some gas.
     
    #4 Spradilak, Jan 1, 2024
    PriusCamper likes this.
  5. pasadena_commut

    pasadena_commut Senior Member

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    Can the OP please post a picture of the broken plug? I'm curious how it broke.

    Some devices like that "break" when the plastic temporarily deforms enough to jump off its retaining post, and in those cases, they can often be reassembled and will work fine afterwards. If the plastic actually snapped or bent, well, that shouldn't be repaired.
     
    #5 pasadena_commut, Jan 4, 2024
  6. Mendel Leisk

    Mendel Leisk EGR Fanatic

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    With current "issues", OP will need to post the pic somewhere else, say Google Drive, iCloud, and provide a link here.
     
    #6 Mendel Leisk, Jan 4, 2024
  7. PriusCamper

    PriusCamper Senior Member

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    cut and paste photos still works for me...
     
    #7 PriusCamper, Jan 4, 2024
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  8. ChapmanF

    ChapmanF Senior Member

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    #8 ChapmanF, Jan 4, 2024
  9. Spradilak

    Spradilak New Member

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    #9 Spradilak, Jan 4, 2024
  10. pasadena_commut

    pasadena_commut Senior Member

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    #10 pasadena_commut, Jan 5, 2024
  11. Spradilak

    Spradilak New Member

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    I found one about an hour away for $40. If I didn't absolutely need the car the next day I would have just ordered one from ebay for $15-$20 but I guess you have to pay for convenience. But thanks for the link!
     
    #11 Spradilak, Jan 5, 2024
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