Prius Battery Replacement Kit (GenII/GenIII) with NEW custom cells

And I too will probably be joining this group, my trusty 06' prius with slightly over 70k with no out of ordinary problems just developed the symptoms of a bad HV battery. Heard a couple of pops now back there recently, after doing some checking of things like the fan blower which I've never heard, it gave another loud pop today going 40mph on level ground in the morning when it was relatively cool outside, then heard it sizzling maybe arcing a bit so I rushed home and pulled the safety plug. Am leaning on getting one of these kits and install it. Should give the car an extension in life, and possibly save it from a triangle of death and a tow home..I contacted Nick and he said this week! Anxiously waiting.

 

That reminds me of The battery fires at ECU sense connector thread.

Before you begin rebuilding the battery, I suggest that you unplug the orange connector that connects the voltage sensor wiring harness to the battery ECU, and inspect it thoroughly. If it shows signs of corrosion or arcing, then you should replace the connector along with the voltage sensor harness and/or Battery ECU.

 

Yes I've already disabled the battery and parked the car, as soon as I heard arcing. Actually I pulled the neg. of 12v battery as well, until I get done with this. No sense in letting it go dead too. Hopefully I will receive the kit in time...

 

1500 miles later, MPG is back to 'normal' (high 40s city, low 50s highway). Here's a temperature graph from a recent trip (Torque, BAFX, plotly)

 

Just ordered Gen2 battery from newpriusbatteries web site for my ‘05 Prius with 250,000 miles. Hopefully it gets here in California soon as I’ll be on vacation next week to work on it.

 

(Above is the not fully assembled yet kit. Also, installed backwards.. I touch on this topic later)

Received the kit, nicely padded packaging. Modules and molding look great. The tabs that protect the terminals are difficult to take off without breaking, so it's nice that some extras were included.

The car drives a bit smoother. More EV only driving without the ICE kicking in. Only put about 200 miles on it so far and I've heard the ECUs need to re-calibrate themselves for optimum performance.

My old battery would go to 1-2 bars in the morning/after work, then charge up and rapidly go to green/blue indicating the battery was close to failure. This one does not dip in the morning/evening. Battery stays in the blue/green bars, nothing purple/red.

Instructions were a bit tricky. These are a newer version kit (Version-3) from the seller. This means that the manual that's already been claimed to be tricky just got trickier. Labels have been revamped/reworded. The batteries now have female connections, you stick a bolt in the module versus the older kit which you would stick a nut on the end of a male bolt head on the module.

I think the seller could benefit from labeling things a bit clearer in illustration. Such as maybe add a sticker indicating which battery should be closest to the ECU. "ECU Side" or something along these lines. I originally installed my battery with module 14 (close to ecu), module 1 (furthest from ecu) per the outdated manual, however found I had to disassemble the battery and order them from 1 (close to ecu), to module 14 (furthest from the ECU).

Maybe they could also add note which side the red side of the harness versus the blue side of the harness should face? Here's a little illustration I whipped up with a few minutes in paint of my setup that might be helpful to some! Make sure to install everything in the correct order though to avoid electrocution.



Overall enjoying it, nothing negative to report and there are only positive results.

 

Well that is odd.

I presume the numbering to which you refer is the module serial numbers.

It seems odd that they should be opposite to what Techstream numbers them. They also seem opposite to your V numbers, whatever they are.

Also looking at your diagram, the +'s and –'s seem a little odd. Are you sure you got that right?

Glad it is all together and the car is running well. Congratulations on a job well done.

 

Dolj: Oops! I messed up and put the wrong the voltage on the main wires. (Unfortunately I can't delete the wrong image in my previous post, but its fixed below.) Techstream is fine and not opposite. I was referring to the way the kit's manual is labeled is opposite. Nick sends out an email that explains the changes in the Version-3 kit when you place an order, but I had missed it starting my install.

 

That may make sense in context of the manual, and I wonder if they have a generic instruction set that covers both Gen 2 and 3, as the Gen 3 battery modules are labelled that way. As far as the way the battery works, it probably doesn't matter whether you stack them 1 – 14 or 14 – 1, unless the caps on 1 and 14 are different.

However, any diagram that represents a Gen 2 battery (especially presented here on PriusChat) should show the module count as it in Techstream, as per this:


Perhaps, you could feed this back to Nick, for his consideration.

 

Oh I see what you are referring to now!

The black plastic parts of the modules are removable - it's possible they could be swapped around the right way (?) but I didn't look into it that much however and proceeded to just install them in reversed order. It hadn't made sense to me why it was 14-1 until you indicated this is the way the blocks are oriented in the computer.

 

A new compete Toyota battery sells for $1657. Why someone wants to pay $1600 for aftermarket modules to build a battery?


2006 Toyota Prius HYBRID Battery assembly, hv supply. Electrical, wiring, cable - G951047031 | DARCARS Toyota, Frederick MD

 

I was struggling with what happened in the above picture revisions, made this cheat sheet:

 

So which picture is correct?

 

Bottom one I think? They're in the same order as posted, descending.

 

Well, many dealers will not sell you the battery without installation. Many more dealers will not ship a battery pack. You need to deal with the core fee that you conveniently omitted. If they actually sell you a pack, it will only have a one year warranty.
The majority of the $1600 cost for the kit is for shipping. The design with cylindrical cells improves the cooling air flow.
In my experiences, many Toyota dealer service departments are incompetent when it comes to service g the Prius.

 

I installed these batteries in my car last night. This morning noticed my right rear window will no longer move up when I push the button. I’m thinking I must have disconnected something. Any ideas?

 

@2k1Toaster with the Toyota website you pay online and pick up the part at the dealer when they send an e-mail saying the part arrived. I don’t know how they would handle the return as I have not done it myself. At least not for a traction battery. All my other purchases go fine though.


Toyota Parts Center Online | Genuine Toyota Parts & Accessories

 

I highly doubt they would refuse to give it to you. They could just say it’s not for sale like Olathe Toyota does. As I say this isn’t going to a dealer with internet price in hand and asking for that price. This is actually buying the part from Toyota with the dealer as the middleman. I think Toyota would have a problem with that. That’s why dealers like Olathe don’t offer it for sale. I’m guessing whoever the Toyota dealer you talk about doesn’t offer it for sale either.