1. Attachments are working again! Check out this thread for more details and to report any other bugs.

2005 Prius w bad hybrid cell

Discussion in 'Gen 2 Prius Care, Maintenance and Troubleshooting' started by Aryiana, Apr 13, 2009.

  1. Aryiana

    Aryiana New Member

    Joined:
    Dec 14, 2005
    5
    0
    0
    Location:
    PA
    *Threads Merged
    We have a 2005 Prius that we purchased in December of 2005. My husband drives 1K miles a week for work and as of today there are 152,652 miles on the car. Other than having to have the headlights replaced (at a cost of $350/each - which Toyota DID reimburse us for since we were already over 100K miles at that point) we have been pretty trouble free with our car... until today.

    Over the weekend my husband drove our daughter to a friends house and returned (about a 14 mile trip). When we got in the car about 20 minutes later, the dash lit up with the exclamation in the triangle, VSC, and the engine icon, while the display had another icon which I found out was the hybrid battery light.

    Long story short, we have a bad cell in the hybrid battery and since the car has over 100K miles, the "District Parts and Service Manager" (aka: He Who Thinks He is G-d) declined a goodwill consideration to replace the battery under warranty even tho the car has only been ours for 3 years 4 months. I called Toyota Corporate and apparently they don't/won't override this jerk's decision.

    Anyone have any suggestions?

    I am waiting for a supervisor from Toyota Corporate to call me back (within 24 hours) when I will again try to plead our case and am trying to get any and all information that may help us (such as the 150K warranty period in CA).

    I am quite upset and frankly very ticked off that Toyota will not do anything for us and in trying to research this online all I am coming up with is that people will be close to 8 years when/if it the battery would fail and no one has heard of anyone having to pay to have their battery replaced (none have apparently failed out of the warranty period of 8 yrs/100K miles -- well except for ours).

    We purchased a Prius because of the miles my husband travels, however, this battery will zero out any money we will have saved on gas so far :(
     
  2. Bob_Stan

    Bob_Stan New Member

    Joined:
    Mar 31, 2009
    70
    5
    0
    Location:
    Central New York
    Vehicle:
    2011 Prius
    Model:
    Four
    I am sorry to hear about your problem, but the warranty is 8 years OR 100,000 miles, whichever comes first. I can see why you are disappointed, but the vehicle battery has exceeded the warranty period, even for California.
     
  3. Aryiana

    Aryiana New Member

    Joined:
    Dec 14, 2005
    5
    0
    0
    Location:
    PA
    Yes, Thanks Bob, I CAN do the math.... however, it has also been published that there is a .0003% failure rate in Gen. 2 Priuses (from 2004 - May 2008) with only 23 cars having a post-warranty hybrid battery failure. With this low of a rate, and with having only 3 years with the car, Toyota SHOULD stand behind their product. That is the point.

    I hope this doesn't happen to you -- people may be just as sympathetic as you are.
     
  4. Patrick Wong

    Patrick Wong DIY Enthusiast

    Joined:
    Mar 8, 2008
    18,200
    6,474
    0
    Location:
    Green Valley, AZ
    Vehicle:
    2015 Prius
    Model:
    Two
    Re: 2005 Prius w bad hybrid cell (x-post)

    Sorry to hear about your problem. There are a good number of Classic traction battery failures out of warranty and those owners have had to pay for replacements. 2G battery failures have been much rarer but its not realistic to expect those batteries will last forever.

    One alternative you have is to purchase a battery from a salvage vehicle which should cost $350 - $600 plus shipping, and have an independent install that battery for you. For example:
    http://motors.shop.ebay.com/items/__prius-battery_W0QQ_kwZpriusQQ_kwZbatteryQQ_ckwZtraction

    The necessary repair manual documentation including safety precautions can be found at techinfo.toyota.com
     
  5. jayman

    jayman Senior Member

    Joined:
    Oct 21, 2004
    13,439
    640
    0
    Location:
    Winnipeg Manitoba
    Vehicle:
    2004 Prius
    If its just a bad cell, I would look into salvage batteries. There is no freaking way I'd pay for a new pack over one cell

    Let me guess: +$2,500, right?
     
  6. richard schumacher

    richard schumacher shortbus driver

    Joined:
    Mar 27, 2004
    7,663
    1,038
    0
    Location:
    United States
    Vehicle:
    2004 Prius
    Model:
    N/A
    Re: 2005 Prius w bad hybrid cell (x-post)

    Before spending a lot of money, get a second opinion from another dealer.

    Did you buy it new, or used?

    Patrick, is it reasonable to replace only the failed module? Or do they all have to be matched?
     
  7. richard schumacher

    richard schumacher shortbus driver

    Joined:
    Mar 27, 2004
    7,663
    1,038
    0
    Location:
    United States
    Vehicle:
    2004 Prius
    Model:
    N/A
    [what th' hell...?]
     
  8. Patrick Wong

    Patrick Wong DIY Enthusiast

    Joined:
    Mar 8, 2008
    18,200
    6,474
    0
    Location:
    Green Valley, AZ
    Vehicle:
    2015 Prius
    Model:
    Two
    Re: 2005 Prius w bad hybrid cell (x-post)

    Hi Richard,

    It is possible to replace only the failed module if you can get that module SOC to be close enough to the other modules so that, under load, the module voltage does not vary by more than a few tenths of a volt from the other modules. However this will not be easy to do.

    The OP's description of her car's symptoms support the diagnosis of a failed battery module. If she can get the DTC that was logged, this will provide further evidence to support or refute the diagnosis.
     
  9. efusco

    efusco Moderator Emeritus
    Staff Member

    Joined:
    Nov 26, 2003
    19,891
    1,192
    9
    Location:
    Nixa, MO
    Vehicle:
    2004 Prius
    Model:
    N/A
    Re: 2005 Prius w bad hybrid cell (x-post)

    1) being upset is reasonable, nobody likes paying for expensive repairs. We had to pay over $2000 for a rebuilt transmission in our old Ford Windstar b/c it was just over 100k miles. But expecting Toyota to eat this is, IMO, unreasonable on your part. Even if you were in a California emissions state you're beyond the 150k warranty there. I don't blame you for taking it up the chain of command, but I don't think you have any solid footing for expecting them to take care of the cost any more than you would if the engine had blown or a transmission failed on any conventional car.

    2) Buying a brand new battery, with the amount of driving your husband does, seems reasonable, but looking for a salvage battery is a reasonable option. There are places who can do the install for your for a fair price and you can likely save a couple thousand dollars that way.
     
  10. yardman 49

    yardman 49 Active Member

    Joined:
    Mar 26, 2009
    606
    77
    0
    Location:
    Northern Kentucky
    Vehicle:
    2009 Prius
    Hello Aryiana:

    Certainly unexpected expenses can be stressful. I don't mean to rub salt in the wound, but I'm curious as to why you are upset, and why you refer to the District Service Manager as a "jerk" (although some may certainly be!).

    It seems that you live in PA, and your car has over 150,000 mile on it. So you are 52,000 miles over the normaly hybrid battery warranty. Even if you lived in CA, you'd still be over the 150,000 mile warranty that you mentioned. And it seems that Toyota has previously done you a favor by reimbursing the cost of your headlights replacement at over 100K miles. In addition, you state that things have been pretty much problem free.

    From my viewpoint, you don't have a right to be angry about this at all. It seems that both the Prius and Toyota have treated you pretty well so far.

    Remember, "goodwill" gestures are just that: goodwill. They are not required, nor should they be expected to be required. Otherwise the concept of "goodwill" means nothing, and the act is just a duty owed, or payment for a service rendered. When you are given a gesture of goodwill, give thanks. If you don't get one, don't show "badwill" by complaining about it.





    Now as far as loosing all the gas savings, I would say that there are other features about the Prius that have been saving you money, without you being aware of it.
    • For instance, most users have to get their brakes replaced much less frequently than owners of regular cars. This is due to the hybrid engine providing a large percentage of the cars "non-panic" braking.
    • Many engines on small cars are what are known as "interference" engines, meaning that if the timing belt broke, the valves would crash into the cylinder heads and ruin the engines. Because of this, manufacturers often require timing belt changes at 60K, or 100K, or some other interval. These belt changes are not cheap. To the best of my knowledge, the Prius G2 uses a timing chain, which is more robust.
    • I haven't seen any reports on the forums yet about G2 exhaust systems needing any major work done.
    I'm sorry to hear about the battery problems. Hopefully you can indeed find a less expensive means of getting the Prius repaired.
     
  11. efusco

    efusco Moderator Emeritus
    Staff Member

    Joined:
    Nov 26, 2003
    19,891
    1,192
    9
    Location:
    Nixa, MO
    Vehicle:
    2004 Prius
    Model:
    N/A
    B/C they make such a reliable car when that 1/3333 event occurs that means that Toyota should eat the cost? So if the battery failure rate was, say, 1:100 you'd be ok with paying it? You're really not being logical.

    It is sad and bad luck that you had a failure. As I described I can totally feel your pain and I personally know how such expenses suck when they occur. But you're being completely unfair in expecting Toyota to cover beyond the warranty period...it was a contract you agreed to at the time of purchase..
     
  12. KTPhil

    KTPhil Active Member

    Joined:
    Jan 14, 2005
    1,379
    20
    0
    I would also feel like I got a "lemon" of a Prius. But this is only in relation to the average and typical lifetime of the batteries. 150K is as long as many engines last, so if you can find a used battery that gives you another 50-100K miles for under $1K, you will have gotten a respectable 200K miles out of the combo of purchase price and this battery cost. That may well be a per-mile cost below the average "small midsize" sedan made by others.

    I'd still feel I got a "bad one" but overall 150K miles without a hitch is pretty darn good for a modern complex car. Hearing abotu taxis going 2-300K without problems leads us to expect them to be bulletproof, but of course they are not.

    Good luck with Toyota (maybe they will help you find a salvage car with a decent battery or make some other gesture). And good luck with your replacement unit.
     
    1 person likes this.
  13. Aryiana

    Aryiana New Member

    Joined:
    Dec 14, 2005
    5
    0
    0
    Location:
    PA

    Yup... $3000 including labor :(
     
  14. Aryiana

    Aryiana New Member

    Joined:
    Dec 14, 2005
    5
    0
    0
    Location:
    PA
    Re: 2005 Prius w bad hybrid cell (x-post)

    We bought it brand-spankin' new and have done all the recommended services, and oil changes every 3-5K miles. I was told they don't replace the individual cells and from what I have read in my researching is that they don't replace the individual cells for the same reason you always want to change all the batteries in any battery-operated thing.... so that you don't mix old and new.
     
  15. donee

    donee New Member

    Joined:
    Aug 15, 2005
    2,956
    197
    0
    Location:
    Chicagoland
    Vehicle:
    2010 Prius
    Model:
    III
    Hi Aryiana,

    156K is 156K. Get on Ebay, or call AutobeYours.com and get a salvage battery if the transmission fluid and engine oil were maintained. Do you really get 156 K out of a automatic transmission? By buing a Prius you probably got 1 1/2 the lifetime before major repair expense.
     
  16. Aryiana

    Aryiana New Member

    Joined:
    Dec 14, 2005
    5
    0
    0
    Location:
    PA
    Thank you for finally articulating where I am coming from with this. Actually, I did get a call back from Toyota Corporate and they are going to send this to a case manager. In backing up my points with facts (such as the dealer we go to has sold thousands and this is the *only* G2 battery that has failed without MVA being the cause), I think they are willing to look at it a bit closer.

    My husband had a 2002 Hyundai, and altho we only got 24 mpg with it, we gave it to a friend with 130K miles once we bought our Prius -- and he never had an issue with that car either. Bottom line, if we were going to get a "bic lighter" car (one that we would just give up/trade/whatever in 3 years) we would have gone alot less expensively than a Prius -- and broken even ... albiet paying more for gas in the long run.
     
  17. jayman

    jayman Senior Member

    Joined:
    Oct 21, 2004
    13,439
    640
    0
    Location:
    Winnipeg Manitoba
    Vehicle:
    2004 Prius
    Salvage battery, they are available.

    If I had kept my '04, and it threw a battery code, I'd just look for a salvage battery myself. BTW: a taxi operator bought my Prius, with close to 200,000 km on it. He didn't seem to afraid of lurking repair issues

    Question: have you changed the transaxle fluid? Wouldn't be a bad idea to do so. One of our newer members, a mechanic, picked up a used Prius that ate the transaxle. He replaced all the parts himself with salvage parts, works fine
     
  18. fuzzy1

    fuzzy1 Senior Member

    Joined:
    Feb 26, 2009
    17,317
    10,167
    90
    Location:
    Western Washington
    Vehicle:
    Other Hybrid
    Model:
    N/A
    If 23 cars represents a .0003% failure rate, that means a population of about 7,000,000 Gen2 Priuses under consideration. Sorry, that exceeds worldwide production.

    One of these forums (priuschat or cleanmpg) indicates that used (collision salvage) Gen2 battery packs are selling for $400.

    But a dealership is likely to refuse to install anything that isn't factory new, so you may need to find a good independent shop to do it. I moved my Honda business to an independent Honda/Toyota shop to get a permanent fix for half the price that the dealership wanted for a temporary fix (factory replacement part having the same weakness as the original). Unfortunately the spouse couldn't reach me when her Acura had the same problem, so she paid full price for the temporary fix. In the decade since, both cars have had all their (infrequent) repairs done at the independent shop, with excellent customer satisfaction at lower prices.

    The only difficulty with independent shops is finding the good ones.
     
  19. saechaka

    saechaka Member

    Joined:
    Dec 1, 2004
    225
    18
    0
    Here is what I would do if I was you. It sounds like you are covered to 150,000miles. Chances are good your car was reading 2mph faster than it really is going. I did a rough calculation that my odometer was reading 10% off for every 5 miles. I would use the speedometer check stations and for every 5 miles my odometer read 4.9 miles. So every 50 miles, my car reading was off by 1 mile. This was with stock tires inflated at 42/40. So it seems your car logged 3000 more miles than actually driven based on my figures. You will somehow need to prove that your odometer is off though. Just a thought. Good luck
     
  20. patsparks

    patsparks An Aussie perspective

    Joined:
    Jul 12, 2007
    10,664
    567
    0
    Location:
    Adelaide South Australia
    Vehicle:
    2004 Prius
    Model:
    N/A
    My brother just spent $5000 on repairs to his late model Nissan Patrol, way under 150,000 miles on it, then he had to spend another $6000 when it broke down a few months later. I asked him if there was a shortage of Toyotas when he bought the car? I have no idea why he bought a Nissan. $11,000 in repairs over 6 months would upset me but if it happens you wear it, that's how it is. You play the odds and as you say, your odds are excellent with a Toyota but unfortunately sometimes you still lose.
    I'm sorry you had a battery cell failureAryiana, it isn't good no matter how rare it is. When it happens to you and you have only one Prius it equals 100% failure rate to you. I hope you find a good resolution.