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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    IMG_2452.JPG

    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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  10. Albert Barbuto

    Albert Barbuto Active Member

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    I have seen in the past new oem modules for half the above prices.

    On to another subject. I was curious if a broken stud could be professionally repaired, so I took apart a bad module. There does not appear to be enough metal to drill and tap for a new stud. :(
     

    Attached Files:

    #10 Albert Barbuto, Feb 19, 2026 at 1:36 AM
  11. Prodigyplace

    Prodigyplace 2025 Camry XLE FWD

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    how, since Panasonic ONLY sells them to Toyota and Toyota does not sell them individually?
     
    #11 Prodigyplace, Feb 19, 2026 at 8:29 AM
  12. Prodigyplace

    Prodigyplace 2025 Camry XLE FWD

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    #12 Prodigyplace, Feb 19, 2026 at 8:33 AM
  13. Hayslayer

    Hayslayer Active Member

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    If I could sell new modules for $175 each, I would be happy to buy dozens of new HV batteries, break them down and sell individual modules. One 28 module pack = $4900, that's a pretty good margin.

    Or buy a Camry pack, use 28 to rebuild your pack and sell the rest. Plenty of options actually, but I just don't know there would be high demand for individual 'new' modules. A new module in an old pack is a recipe for problems.
     
    #13 Hayslayer, Feb 19, 2026 at 9:30 AM
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  14. Kenny94945

    Kenny94945 Active Member

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    I do not know.... but that broken part arrears to be removable.
    Is it replaceable?
     
    #14 Kenny94945, Feb 19, 2026 at 9:39 AM
  15. jdenenberg

    jdenenberg EE Professor

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    The AWDe Gen 4 Prii use NiMH modules, not the newer Li-Ion ones.

    You could take that module to a machinist to find a solution.

    JeffD
     
    #15 jdenenberg, Feb 19, 2026 at 10:39 AM
    Last edited: Feb 19, 2026 at 4:39 PM
  16. pasadena_commut

    pasadena_commut Senior Member

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    NiMH. The metal is not Cadmium.
     
    #16 pasadena_commut, Feb 19, 2026 at 2:31 PM
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  17. jdenenberg

    jdenenberg EE Professor

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    Thank's, Corrected
     
    #17 jdenenberg, Feb 19, 2026 at 4:40 PM
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