Damaged my new Hybrid battery

Discussion in 'Gen 2 Prius Care, Maintenance and Troubleshooting' started by Ctrain24, Feb 16, 2026 at 6:55 PM.

  1. Ctrain24

    Ctrain24 Junior Member

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    I just bought a brand new hybrid battery from Toyota for my 2007 Prius and in the process of installing the large orange wire harness onto the battery, I over tightened one of the nuts and sheared off a stud on one of the cells. Would there be any issues installing a single reconditioned cells in place of the damaged unused new cell? Does Toyota sell individual cells new?
     
    #1 Ctrain24, Feb 16, 2026 at 6:55 PM
  2. ChapmanF

    ChapmanF Senior Member

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    Ouch. Toyota doesn't sell individual modules.

    You could put in a reconditioned module, but unless it is very close to new in performance, it will be the limiting factor in the performance of the whole pack.

    If you haven't bought a good-quality inch-pound torque wrench, it's good to have for this job.
     
    #2 ChapmanF, Feb 16, 2026 at 9:05 PM
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  3. Ctrain24

    Ctrain24 Junior Member

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    Would you advise on installing the reconditioned module in the same spot as the current damaged one or towards the front for easier access in the future? Right now I have to remove 18 of the modules to get to the 19th one.
     
    #3 Ctrain24, Feb 17, 2026 at 4:39 AM
  4. Ctrain24

    Ctrain24 Junior Member

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    20260217_073225.jpg 20260217_073223.jpg 20260217_073157.jpg 20260217_073225.jpg 20260217_073223.jpg 20260217_073157.jpg
     
    #4 Ctrain24, Feb 17, 2026 at 8:24 AM
  5. Albert Barbuto

    Albert Barbuto Active Member

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    You will find brand new factory modules at eBay.

    Yes, a torque wrench is a very wise "must have". Pictured tool is what I purchased when I replaced my hybrid pack.
     
    #5 Albert Barbuto, Feb 17, 2026 at 12:00 PM
  6. hurricos

    hurricos Junior Member

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    Damn, you folks torque them? I just replace the terminal plates, and set my Bosch IDH182 impact on the lowest setting and give it one "dugga". I've rebuilt three batteries this way.

    I feel like I might be a heathen.
     
    #6 hurricos, Feb 17, 2026 at 12:14 PM
  7. bisco

    bisco cookie crumbler

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    I was unable to find any new modules on ebay
     
    #7 bisco, Feb 17, 2026 at 1:32 PM
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  8. Albert Barbuto

    Albert Barbuto Active Member

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    #8 Albert Barbuto, Feb 18, 2026 at 9:44 AM
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  9. bisco

    bisco cookie crumbler

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    Thank you!
     
    #9 bisco, Feb 18, 2026 at 1:05 PM
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