Gen 1 - HV Traction Battery removal the easy way.

This week I had the chance to clear P3009 errors on two of my Gen 1, 2002, Prii. I followed advise on the Internet videos by taking out the traction battery through the side door. Now, I'm almost 66 years old and it's a bit difficult to get the battery out that way. I had two strong young men come over and give me a hand manhandling the battery out and put it on a work bench.

There had to be a better way. I think I may have found it. Here's what I did:

• Remove all bolts, carpets, etc. necessary to remove the HV battery
• Placed two 8' 2X4's in the trunk sticking out the back.
• Used a flat wrecking bar to lift up on side of the battery and slid the 2X4 under the battery.
• Did the same for the other side.
• "Walked" the battery toward the rear of the car on the 2X4's.
• Walked the battery out over the end of the car.
• The 2X4's went down with the weight of the battery.
• At the end of the 2X4's I placed a carpeted Harbor Freight moving dolly
• Continued to walk the battery down the 2X4's.
• Placed the battery on the moving dolly

Now I can move the battery anywhere I want in the garage with ease. I could just have easily moved the battery up to a portable workbench using this method. I could also rig up a sling to my engine hoist and move it up to a non portable workbench.

It took me 7 minutes to get the battery out. It took me 5 minutes to get the battery back in using the reverse procedure. Again, I'm am almost 66 years old and had polio... I think you guys could do it in better time!

In reinstalling the battery, when the battery was relocated over the holes in the body of the car I placed two long punches to hold it in place over the holes. Then I simply slid out one 2X4 and then the other. The battery came down perfectly aligned in place. I never even broke a sweat.

I suspect this would also work with a Gen 2 Prius, someday when my Gen 2 dies, I'll get that chance too.