Smoke from rear interior after acceleration

Those are the prices you'll usually get, because the usual reason people are calling about their battery is age and degraded capacity, which tends to affect all the modules at around the same time, so when that's the problem, nobody's very keen on replacing single modules, because it will just turn into a game of whack-a-mole.

You've got a more unusual, distinct situation. You just have one module that got scorched, probably because of a badly torqued nut or a manufacturing defect. In your case, I agree with JC91006 that it might be very reasonable to replace just that module (and check all the bus nuts carefully, and torque them all carefully to the right spec).

If it were me, I'd probably get the replacement-parts kit (04003-35147) which will include new bus straps and wiring and nuts and such, pretty complete hardware overhaul for about $100, plus one module, for whatever those are going for these days, $50ish?

The trick is to determine the average capacity of the good modules you've got, and try to get as close as you can to that with the replacement module. That's what can complicate an otherwise simple job.

But for that matter, I'd take out whichever module seemed to be implicated in the scorching, and test it. In my mind, this kind of scorching is at least as likely to have been caused by a poor bus-strap connection as by anything with the module itself. If it seems undamaged / not melted or misshapen / any soot cleans right off, and if it tests out as a good capacity match to your other modules, you might be better off just putting it back in (with careful terminal cleaning, new bus straps, and undivided attention to the nut tightening torque).

-Chap

 

you need to read the battery rebuilding threads. see the one by member, '@ryousideways'

 

i honestly can't believe you're still driving it. do you carry a fire extinguisher?

 

Hmm, possibly, depending on your dedication. Definitely a new ECU is in order, as well as the rebuild hardware kit (which includes the wire harness with the orange connector that melted). Plus at least one module to replace the split/melted one, plus your time and attention to detail in checking the condition of all modules to find any other injured ones, and figure out what the average capacity is, and try to obtain replacements roughly matched in capacity.

Plus cleaning everything really well, because that connector going foom probably left sooty gunk everywhere that may be conductive and lead to ground fault codes.

If that sounds like a fun DIY project, then maybe it is, and if it sounds like a PITA, well, that too.

-Chap

Edit: wait, wait, wait, you're talking about a 2007. i forgot, the part number for a rebuild hardware kit that I gave you upthread was for a Gen 1. You'll have to look up the parts you need for a Gen 2 battery.

I've added your incident to the battery fires at ECU sense connector thread (which started as a Gen 1 thread, but hasn't stayed that way).

 

Do not order that kit. It is for a 2001-2003 Prius and will not fit your 2007. I had a brain fart.

Just go to any of the online dealers with the battery components illustration for a 2007, and look up the front bus cable assembly with the voltage sense wires.

-Chap

 

That's the stuff. If it were me, I'd buy new. If you go used, look it over carefully, referring to the connector condition photos in the 'battery fires at ecu sense connector' thread.

-Chap

 

Hey, I cringe a little at that photo of bare finger next to vent tube and blown-open module. I guess you haven't been unlucky (or you'd have noticed by now), but potassium hydroxide turns skin, eyes, etc. into dead goo.

-Chap

 

Has your battery ever been repaired? I think replacing the damaged modules would be enough to fix your problem

 

I think that green wire is one of the four temperature sensors.

 

look at the serial number of the modules, the one that caught fire and the ones around them (so total of 2 additional per side, 5 total). write them down and post them.....I'm curious if those are original to the pack or replaced modules.

 

I have seen modules with the tops blown off that still work! You have a whole bunch of work ahead of you.

Brad