Had Hybrid battery rebuild and still getting code to replace battery

Apparently the Gen 4 trim 2 NimH modules are the same size as the Gen 2 modules. Just different on the top slightly in appearance. So no restriction from using Gen 4 trim 2 modules with Gen 2 packs. Of course, there would be difficulty getting module pairs into blocks with roughly matching capacities. That would be tough but not impossible to do.

So it's not clear to me whether or not one would need all 28 Gen 4 trim 2 modules for a Gen 2 Prius. It would probably best to do so anyway.

 

I'm told that the best match comes from having all cells from the same donor battery.

 

My understanding is that it is not recommended to mix modules from different generations in the same pack.
I know Toyota has said they have improved the Nickel quality in Gen 4 packs. I would expect they made improvements in the Gen 3 pack over Gen 2 too.

 

I found a dealer in Lansing that sells the genuine Toyota battery for less $1780.

 

IIRC, Todd got a Gen4 pack from a wreck, that only had a few thousand miles on it.

For reliability, you would want to all the modules of similar age, resistance, etc. Makes sense to transplant all the Gen4 modules, from the donor wreck, into a Gen2 case. I'm sure the Gen2 driver, w/ the Gen4 modules, is good for another 8-10years! Pretty much a new battery for the cost of a rebuild, but the longevity and reliability of a NEW OEM HV Pack.

 

My point was is that it's not mandatory. You could mix and match the modules from Gen 2, 3, and 4 (trim 2) since they're the same size, voltage, and capacity. This isn't rocket science.

Greentech and Dorman will be combining Gen 3 and Gen 4 modules some day - if they're still in business five years from now.

fotomoto said that the use of Gen 4 modules REQUIRE a complete exchange of all 28. That is false.

 

Dorman is a large, international, publicly-traded company. They aren't going anywhere. Their product line is diversified. Walk into any parts store across the nation and you will likely find an aisle dedicated to Dorman products.

 

Before Rebuilding a Hybrid pack one must check the packs remaining capacity. Anything below 70 percent is not worth rebuilding. Brand new a prius module for example is 6.5 Amp hour and 4 amp hour is threshold. The problem is simple. The battery whole pack needs to be replaced.