2002 Don't know who to trust

I don't wish to offend and haven't read your posts carefully, but I don't recommend you personally embark on the work people are suggesting, esp. if you've never done any work on cars before beyond changing burned out bulbs or an air filter and have no familiarity w/working w/high voltages.

I'd have either a friend/relative that's familiar w/working on cars (esp. hybrids) or a trustworthy mechanic do it/help you.

Even I don't work on my car beyond fixing/changing very minor things (e.g. changing air filters, wipers, cabin air filters, 12 volt battery, burned out lights). If you don't have the proper tools (e.g. proper sized sockets, torque wrench, etc.), you'd better get them before starting. The type of work people are suggesting is beyond my current capabilities and experience, besides not even having a torque wrench. I put together PCs myself from off the shelf components (motherboard, case, power supply, etc.) but have no experience w/high voltages. I wish I took auto shop in high school...

I believe mellor's automotive is trustworthy (I have no affiliation w/them and have definitely never done business w/them), but it appears they are way too far for you.

 

Don't bother with Gen 1 cells, they are ancient. There are a ton more Gen 2 cars out there getting into accidents every day. Gen 2 cells are newer and better to begin with / lower internal resistance. I would even question any Gen packs the dealer sells.. I mean does Toyota have newer packs they sell for Gen1 with Gen 2 battery modules?

 

Let me suggest a couple of things:

• limit top speed to 65 mph - this keeps the car in an efficient power region and reduces stress on the rest of the systems.
• city driving, 38 mph or less - this lets the car stay in hybrid mode so the engine can auto-shut.
• first 1.5 miles, 25 mph target - try to keep the speed down for the first part of the first trip of the day to allow it to warm-up without burning a lot of fuel. I cut through 25 mph posted neighborhood, a little longer, it pays off later.
• park in shade - it is better to walk across a parking lot to find the car interior as cool as it can be for both the car and the driver.

Bob Wilson

 

Can you ask the person who worked on your battery if they can point out the part on that diagram?
Is it the thing in my attached pictures?

 

Well, since you're warning lights have went away (for now), I suggest you don't jump to conclusions and start fixing stuff that you're not positive is broke. The only thing I would recommend at this point is to change the tranny fluid.
Here's a great guide (step by step w/ pics).
Gen1 Prius Transaxle Service
As I said b4, I don't think there is anything wrong w/ your battery (except maybe burned wires). If there are no lights, that is a good sign but, I would recommend replacing the burned wires. Who knows, that may be your only problem.
It seems that you are getting tons of help here (funny, that always seems to happen when a pretty girl posts here) so, I'm going to bow out b4 too many hands spoil the soup.

Good luck with your car and I hope everything works out for you. I'm betting that it will.

 

To go any further, we need codes from the Prius and not just the generic codes you can get for free from an AutoZone or other car parts store. We really need Prius specific codes, vehicle metrics, and subcodes and I don't care if they come from:

• Scangauge
• AutoEnginuity
• TechStream-Lite
• other Prius specific OBD monitors

We call them "<uncomplementary> lights" for a reason.

Bob Wilson

 

We are talking about the orange bus bars that connect the interior of the traction battery. Those bus bars also have the module voltage sense wires that are connected to the traction battery ECU so that the ECU can keep track of module pair voltages.

SSC 40G is a recall campaign where the Classic traction battery modules were resealed. As part of that repair, the bus bars are replaced.

If SSC 40G was not already performed on your car, maybe you can get that done now, which would result in the dealer tech cleaning the module terminals, sealing them, and installing new bus bars.

The part number for the replacement parts kit associated with that recall is 04003-35147. That kit will include replacement bus bars and may also contain other parts.

The document for this recall is 56 pages long and is a 2.8 MB pdf file. If you are serious about learning more about this, provide your email address via private msg and I will email that file to you. The file is too large to post on PC.

 

http://techno-fandom.org/~hobbit/cars/TIS/ileaf/toyssc/toysspdf/sscsourc/2004/40g/40gtech.pdf

 

Well, I will do my best to continue to help you then but, you are getting great advice from Avi, Patrick and Bob. Here's my recommended course of action:

1) We need to positively identify the part that is burned (and it seems that may be the cause of your lights coming on intermittently). My guess (and I emphasize guess) is that the insulation is degraded on the burnt wires causing it to leak high voltage and thus causing fault p3009 (which is your major fault code). Can you go back to the guy who told you the wires were burnt and ask him to take a pic of it or identify which part it is on the diagram I posted above? Or, is it the part that Avi pictured above? The bottom line is we need to clearly id which part is burnt so we can order that part and replace it or, have it replaced.
2) You could also try to take the car to the dealer and ask about the TSB (which means a Toyota Service Bulletin, not quite a recall but similiar). If you can get them to check your service history (which is available to them and you on the Toyota Owners website (Toyota Owners Official Website: Service Coupons, Owners Manuals, Service Scheduling and More) (you will need to sign up/create an account)). If the TSB has not been performed, see if you can get them to perform it (even if you have to pay it might be worth it). The problem I have with this is, this dealer already told you your HV battery needs replaced and at this point, I'm not comfortable with that diagnosis. Maybe you can try a new dealer but, the new dealer will see the previous dealer's diagnosis.
3) You should also (highly recommended) replace your transaxle fluid. This is one I would either DIY (with help from one of your mechanically inclined friends who has tools) or have it done by an independent shop. If going with an ind shop, provide them with a copy of the procedure I posted a link to above. This will give them confidence they can do it.
As far as the diff between Gen I and Gen II, there are very few and someone who works on Gen II's should easily be able to work on Gen I's.

 

TSB = Technical Service Bulletin and is NOT specific to Toyota.

They are not necessarily at all similar to recalls. Recalls are for safety defects and non-compliance w/FMVSS. TSBs can range from suggestions for certain repairs to just an FYI (e.g. terminology change). TSBs what warranty (if applicable) would cover the repair so that it's free of charge. Recall repairs are free and mandated by law and shouldn't have any warranty expiration limitations.

Here's an informational one, for example: http://www.nissan-techinfo.com/documents/NTB09-039.pdf.