Hybrid battery numbers help needed

This is not unusual, quite normal actually. As long as they are playing nicely with each other, I wouldn't worry. When you install the pack ensure you reset the battery ECU by disconnecting the 12 V battery for 10 seconds. This will force the battery ECU to recalibrate itself.

The generalized nature of this data means we cannot really glean anything much from it.

You mean 0.16, 0.17, 0.2, etc. So like this:

	Module No	Voltage Difference	Notes
1	1	0.16
2	2	0.17
3	3	0.20
4	4	0.20
5	5	0.21
6	6	0.27
7	7	0.27
8	8	0.28
9	9	0.31
10	10	0.30
11	11	0.24
12	12	0.22
13	13	0.18	Changed cell
14	14	0.29
15	15	0.20
16	16	0.19
17	17	0.23
18	18	0.24
19	19	0.22
20	20	0.24
21	21	0.23
22	22	0.23
23	23	0.21
24	24	0.22
25	25	0.21
26	26	0.19
27	27	0.16
28	28	0.16

Modules 6, 7, 8, 9, 10, and 14 might be worth watching but other than that this data does not show anything of concern. The modules are not perfect, but they are old so no one would expect perfection.

A better test would be to run Dr. Prius or Torque Pro while (someone else is) driving and observe individual max/min voltages under load (fast acceleration, medium braking) as reported by either of those apps. If the voltage difference between the highest and lowest block exceeds 0.3 V, then you will have problems you need to investigate.

 

Not a battery master but I do have a couple questions:
1) did you clean all battery connection studs and replace the (corroded) bus bars?
2) did you use a torque wrench to tighten the connection nuts?
3) did you check for corrosion at the battery ecu connector?

Your problem COULD be a connection issue or is more likely that you have old battery modules (same age and use as the one that failed) and you are now playing "whack-a-mole".

Others with more experience will have to chime in about how effective the Prolong charger is when used on a pack that already has faults.