How to swap newer gen 4 hv battery modules

I know this has somewhat been covered but I figured I’d put some info into one post from my recent experience.

05, had the car go into limp mode after about 60 miles of red triangle. Turned out I had two modules reading low (in the 6v range).

I bought a 30k mile nimh pack from a 2016 in a salvage yard and had it shipped for about $1000.

I ended up getting new strips that connect the batteries as the original AND the new battery’s ones were corroded and I didn’t want to spend the time cleaning them. Plus the nuts didn’t look good either. I tried cleaning with vinegar but it stripped the coating off of the nuts and I didn’t think using them would be good.

Interesting fact: Toyota does not list nuts for the 2016 Prius but they do for the 2005. I learned that they are different and the newer ones look better. After 15 minutes of fruitless searching I eventually just had them order 2005 nuts. After all they lasted 180k miles.

well, turns out they have updated the nuts and the listing for the 2005 ARE the same as the 2016.



So I got three new strips, 56 new nuts and the battery.


the two connectors on one side of the modules that tie them together and the single one on the other side that has wires that can get corroded and give false errors:

82670-47040

82670-47070

82670-47080



the nuts (you need 56):

G9291-47011



Last, the battery pack This is the NiMh from a gen4 (2016 in this case)

G9280-47200

 

Here are the videos I used.
To remove the pack:

to break down the pack: