If you've replaced the main G1 traction battery, please tell us here!

[Optimus]

I want to create a G1-specific reference point regarding information replacing the main traction battery. If you've had to replace the battery, please post:

1. year
2. miles at replacement
3. whether you bought new/used/Ebay etc....
4. general reference to who did the work (dealer, non-dealer shop, yourself, etc...)
5. symptoms you had.
6. amount you paid parts/labor or if it was warrantied.

With any luck, we can get an all inclusive thread for G1 traction battery replacements, try to get an idea just how many have been replaced, potential costs, and what symptoms lead up to it. Most of the posts about batteries in the main forum seem to be about the G2 Prius.

[ea8631]

1. 2001
2. 151000 miles
3. new from dealer
4. dealer did the work
5. battery indicator shown it's in full charge (not normal 75%charge but is 100% charge) status but the vehicle behave it's half charge (engine on all the time and accleration abit slow than normal). Several minute later, Check engine light, red triangle and the hybrid light come on (NO hybrid battery light come on). At the same time, the battery cooling fan are in full power. The car is still drivable this time although those things are happened (I drive it like that for around 200km more until it arive my home). Try to reboot the car, all the lights are come off except the check engine light but within a few minute later the situation happen earlier are all happen again.
6. Just under CAD$4000 (warrenties not cover because my prius have 151000 miles on it).

[MontyMan]

I've been commuting in my 2001 Prius since I bought it 18 months ago, and I think the main battery is going. I get main battery warning lights for about a week at a time, then it will go off for a month or two. The warning light occurs more often in Texas summers of 100F (38C). Last time it was in the shop, the readouts indicated some blocks are getting weak, so the occasional battery warnings are no surprise. So far, no other symptoms. The car drives well and gets 45 to 50 mpg. I would like to find technical charging instructions for the batteries used as the individual battery blocks so I can try to equilize the charge to see if that helps before replacing the entire set. On this board I have read countless threads with titles that indicate main battery charging, only to find out they are either (a) Prius Plus conversion threads, (b) do-it-yourself plug-in conversions costing thousands of dollars and which charge the entire bank at once, or (c) bickering matches regarding the above.

I have found a guy with a pullout set from an '02; now saving up some money and deciding whether I want to take a chance.

[Patrick Wong]

1. 2001
2. 61,365 miles, 11/21/2006
3. New battery, warranty replacement
4. Toyota dealer
5. Master warning light and hybrid vehicle icon were on. Engine would run whenever accelerator pedal was depressed. MPG dropped down to low-30s.
6. Warranty repair.

Currently the availability of salvage Classic traction batteries on eBay is limited while the prices are quite high. This is evidence that the incidence of out-of-warranty traction battery failures is at least as high as the incidence of Classic Prius getting into accidents where the vehicle is "totaled".

Compare to 2G where the pricing of salvage traction batteries is still relatively low. Perhaps one solution for an enterprising Classic owner is to buy two 2G salvage battery assemblies (with 28 modules each) and construct one Classic battery (needing 38 modules) using the best out of the pool of 56 modules.

[ChapmanF]

Originally Posted by Patrick Wong

Perhaps one solution for an enterprising Classic owner is to buy two 2G salvage battery assemblies (with 28 modules each) and construct one Classic battery (needing 38 modules) using the best out of the pool of 56 modules.

It's my understanding that Panasonic's plastic-shell prismatic modules were used in the G1 and their metal-shell prismatics in the G2. Are they otherwise dimensionally equivalent - could 38 of the metal-shells be stacked in a G1 battery case and have the holes line up?

-Chap

[Patrick Wong]

Hi Chap,

My understanding is that the Classic vs. 2G battery module dimensions are similar but not exact. For example the terminals come out of the case at different heights. So it is unclear whether 38 2G modules would fit into the Classic case without any modification required.

[ChapmanF]

Originally Posted by Patrick Wong

So it is unclear whether 38 2G modules would fit into the Classic case without any modification required.

It's looking as if I was mistaken about the 2G using the metal-shell prismatics; apparently it's just the more recent rev of the plastic ones, according to
Toyota Prius Battery Specs - EAA-PHEV

If those are right, the 2G modules are the same width and height, but 10mm longer; that probably means that a new cover would have to be fabbed and would protrude farther into the trunk, and possibly new bottom and end plates. Maybe the existing busbar modules could still be attached to (one set of) the (now doubled) terminals.

It might make for a nice battery upgrade though.

-Chap

[rapidroy]

Hi, Has aneybody out there tried to fit a G2 module into a G1 Drive Battery? if so let us know. Also has aneybody bought a SSC40G mod kit? if so where did you get it? Another question. Dose aneybody know or have read aneywhere how much differance in module voltage is required to set the battery code P3006? Thanks
Roy

[BJ1945]

1. I have a 2001 Prius.
2. Mileage =120,000
3. Bought new from Toyota dealer.
4. Warning light in dash went on (triangle with ! in middle).
5. Also warning light in display went on (picture of car with ! in middle).
6. Took to dealer, diagnostic showed one cell was dead.
7. Approx cost to replace: $3000 for battery. Labor $600.
8. Picking up today from dealer.

[walkinghat]

At 107K mile catastrophic failure (cell). Dealer replaced after some debate. Wanted $3500 then half that then free.
160 K now