Rebuilding a Gen 1 battery

Did you make certain that all of your modules were at the same voltage. They need to be all the same or the ECU will complain with a code.

JeffD

 

TO FORCE CHARGE: Put the car in ready,step on brake pedal, make sure Emergency brake is on, put in drive, and while continuing to keep foot on brake pedal push down on accelerator pedal. Within 1-2 minutes the charge display shoul go up to 6-8 green bars. However as to internal resistance, voltage balance and capacity of individual packs, I cannot say. The best sites to look at is Bob Wilson, he is always doing quite a bit charging and balancing of battery packs. It is quite involved and a special charger is require, and test equipment....However saying all that, we have had post where a guy removed the whole battery pack, installed the 1-2 packs that were low, reinstalled the battery and then drove off. So, who knows. I suggested the force charge only as a easy option. The unbalance may persist/ or not ??? Let us know. :cheer2:

 

A transaxle replaced by the dealer carries either a 1 year/unlimited miles warranty.

It wouldn't hurt to change your transaxle fluid, with Toyota Type IV.

 

Hi I'm new to this forum. Any help is greatly appreciated. I have a 2002 Prius with 118500 miles from which I took out the battery. The screws were corroded and there was also sticky goo around the terminals. Most of the modules had 8.03v while 4 modules had black stuff coming out from the sides.

My question is: should I just replace the 4 bad modules with another 4 used from gen 1 battery or replace all the modules with gen 2?

Thanks.

 

Read all previous posts on this very thread. It all seems to apply to you also. Send the originator of this thread a private message and ask him what he did? :cheer2:

 

Hi guys, I have a Prius 1 and a salvage battery from prius 2 (with ECU & SMR), because I have acces to Toyota tech info I will try to replace the gen 1 battery with gen 2 battery with the ECU and the SMR also, has anyone tried this before?? could it be possible to do it??

 

No. the Gen1 battery puts out a higher voltage than the Gen2. Do your research. You need to obtain 38 good gen2 modules (there are 28 in a gen2 battery), re-balance them, charge them to the same voltage, and install them in your gen1 battery.

Be careful as these batteries have enough power to kill! Once the bus bars are disconnected, they are safe.

JeffD

 

Hi I need to know how to balance the batteries and charge them to the same voltage.

 

Buy a charger and charge each one to full. That's the easiest way. Keep a fan blowing on the assembly, and don't remove modules from the assembly to charge them -- they blow up like balloons if charged without compression. Good chargers are available on RC car/plane websites. You can also balance them by a complete discharge, but them the car won't start.

 

I agree with you 100%, but changing along with the ecu that monitors the cells may work, the only thing that i have to check is what the inverter and transaxle needs to recieve from the gen 2 battery.

 

You cannot change ECUs because the communication protocol is different. You cannot use a smaller number of modules because the voltage will be too low, making the current that the inverter sees too high, and most likely frying components. It just isn't going to work.

Just get 10 more Gen II modules.

 

Both Seilerts and I have rebuilt HV batteries in the past and helped others to do it as well. You should listen to our advise.

JeffD

 

I managed to recharge the battery on my prius gen 1 using 12 volt charger with variable self amps. I coupled each 2 modules and charged it for 10 minutes each and the car started just when i showed it the key, but the guy that sold me the car gave me 1 salvage battery with ECU&SMR from Prius 2, that is why i asked the question. Now i'm thinking in building a HUD on the dash. Thank you guys a lot for the usefull advices.

 

Have you ever force charged the HV to all green?