rebuilding Gen I hybrid battery

This very forum is full of threads on exactly that. Once you have done a little searching you should have found material covering all of these aspects:

1. What options are available for each choice of any two of (good, fast, cheap) - rebuilding yourself can be good and possibly cheap, often not the fastest solution.
2. What safety precautions are of value
3. Comparison of 1st-gen and 2nd-gen battery modules, and how many modules you can get out of a used 1st- or 2nd-gen battery
4. Ideas for matching capacity and state of charge
5. Where to find the manuals for technical information
6. The service bulletin PDF for the old battery resealing campaign (useful because it has very good diagrams and instructions on how the battery comes apart and goes together)
7. If you're really geeky, how to try to recondition individual modules suffering from water loss.

Happy restoration!

-Chap

 

The best way to rebuild your battery is to obtain 2 gen2 Prius batteries and use the modules from these to rebuild your battery.

Your battery 38 modules with 6cells in each module. The gen2 batteries contain 28 modules with 6 cells in each module. The reason you need 2 batteries.

The gen2 modules are much better than the gen1. If you can only get hold of failed gen2 batteries this does not matter since usually only one or two modules go bad and you will have 56 to work with.

Using a suppermate DC6 or similar charger to to balance and regenerate the modules is slow, work on the rate of one module per day, two chargers halve this time and so on.

John (Britprius)

 

My question is:

How do you know its the battery? You state "the hybrid has failed" What part of the hybrid system has failed? What evidence led you to this conclusion? When your car "stopped dead", what were the indications? Stopping dead can be attributed to many causes including (but not limited to) out of gas, dead 12V battery, failed inverter, failed inverter coolant pump, blown engine, blown tranny etc.

Pls make sure you troubleshoot b4 replacing anything.

 

Something I did not notice. It is sometimes all to easy to go racing ahead without having a solid foundation to build on well spotted.