Red triangle and hybrid warning light, and Check engine light illuminated! Please help!

I don't know if you could recoup the cost. The problem is, you're competing against every established junkyard out there. There's tons of stuff you "could" sell off it, doors, trunk, tail lights, engine, transaxle etc but the only one of those you could easily ship is the tail lights (that makes it tougher). You might eventually recoup your cost but it is a gamble and may take a while. You have to be willing to take that gamble.

 

A simple method would be simply to measure the voltage of each of the 38 modules.

BTW, since the traction battery ECU measures the voltage of module pairs (and not individual modules), I assume that module pair 1 and module pair 4 have been found to be defective. If my assumption is correct, then the actual failed modules will be either 1 or 2 (or both), and either 7 or 8 (or both).

 

DirtBiker,

If this is a 2001 Prius, the outlook for the remaining modules is not good as that generation's modules were not very reliable. People have rebuilt Gen1 batteries successfully using Gen2 modules (or Gen3), but you need 38 modules and that requires purchasing two salvaged Gen2 (or 3) hv batteries. Of course you then would have the opportunity to sell the 18 extra modules (assuming that they all tested good) to help others repair their Prii. Successfully rebuilding an HV battery does take some effort to learn the process from those of us that have done it before and time, but it can be done. You should also look at the option of purchasing a professionally done rebuilt battery from a vendor with a good reputation.

JeffD

 

I developed my understanding of how to rebuild a battery while rebalancing my 27 old modules that still tested good. I have tried to help others in their efforts and you can see my (and other's) posts by searching this forum, but no, I have not written up a full procedure.

The individually balanced modules should have very similar capacities (Amp-Hours), the same resting voltage (within a few hundredths of a volt), and very similar series resistances before reassembly or problems will reappear in a short time. Note that this will often mean that you need extra modules to complete the rebuild.

JeffD

 

What the technician is pointing out is block #1 and #4 swing wildly in both charge and discharge. This is the signature of a module that has almost on amp-hour capacity. Their voltage shoots up fast because they can't absorb a charging current. On discharge, it drops because there is no 'charge' capacity.

In theory, you might be able (on your own) to identify and replace the failing modules and replace. But without measuring the amp-hour capacity of the other modules, it would be 80% of the labor needed to do a rebuild.

GOOD LUCK!
Bob Wilson

 

The other issue is that modules you receive, whether ebay or otherwise will not be amp hour tested.
About all you ever get is gaurantee on voltage, which as you have found out, does not mean much. A battery's resting voltage can be much different than its voltage under load.

It's a lot of time and effort to fully test individual cells. So even if you could buy tested cells they would likely be costly. On top of all that, you would need to to know the amp hour capacity of your own cells in order to know what to ask for.

Most people just roll the dice and take whatever cells they get and put them in, figuring they have to be better than what they currently have in their pack. When it works, that's great.
When it doesn't work, then you will do the process all over again, this time swapping in different cells.
Repeat until everything works well enough to drive again.

Doesn't cost much money to do it this way. But sometimes it becomes such a time-sink it may not be worth it.
Most people have other responsibilities to attend to (kids, school, errands, work) and this is not where they want to spend their time.

 

No, this is a symptom of the failed traction battery. Since it has no capacity, it cannot propel the vehicle.

 

They have to be reasonably matched in all characteristics or the rebuild will have to be done again in a short time. Getting 38 matched Gen2 (Gen3 modules are better) is a pain which is why it is worthwhile to consider a rebuilt HV battery from a vendor with a good track record.

JeffD

 

Dorman has taken over the ReInVolt retail business and Dave Taylor, the ReInVolt founder, is still involved so It should be a good choice.

JeffD

 

Dirtbiker, I think you made a good choice. I just worked with another customer who had tried to do module replacement and it failed. The replacement cells didn't play nice with his existing pack. So after all that work he ended up going back in and putting in a new battery.
Since this is your only car a replacement pack with a warranty will fix the problem reliably.
Best of luck and feel free to call if you get stuck.
Don't forget to fully seat the orange plug at the end of your install.

EV Powers Hybrid Battery Service and Repair
Madison, WI

 

Just be safe and remember to slide the safety plug home after inserting it. Many installers have problems because they fail to slide the safety plug into the locked position (there is a sensor that stops the Prius from starting).

Jeffd