Prius Gen2 Traction Battery Experience

My 2004 Prius began to have HV battery problem symptoms at 194k miles,

• The ICE RPM went higher than normal when accelerating or going up hill
• The SOC fluctuated rapidly
• MPG, however, seemed OK

Then about a week later the dashboard lit up like a christmas tree

The OBD2 code was P0A80 which confirms the failed traction battery. I had expected it to last 250k to 300k miles, Oh well.

My Prius now had some new symptoms since the ecu knew there was a problem:

• MPG dropped a bit
• Cruise control was disabled (Probably AC too, but I didn't check it)
• No help accelerating from the MGs - Only the ICE so a bit sluggish

I checked with Dave at Re-InVolt in NC and he could ship me a refurbished battery for $1475 plus $125 shipping to CT as long as the shipping address was a commercial site. He did not have any installers in CT.

I contacted my usual Toyota dealer and he priced a new battery as $3300 installed. I talked him into pricing using a battery that I supplied and after informing him that it would be a drop in (fully equipped with the required electronics) he said 4 hours ($360 plus tax - installing a Toyota battery is a 5 hour job).

The battery was shipped directly to the dealer and was installed (Dave now has a CT installer). My Prius is back up and running like new. I expect that the Re-InVolt battery starts out with some previous use, so I expect that its life may be about 50k miles less than a new one, but we'll see.

So all in all not a bad experience. Under $2000 after 194,000 miles is a penny per mile (for comparison my tires also run about a penny a mile - $500 every 50k miles).

JeffD

 

I was lucky, Dave had a surplus of salvaged batteries and didn't need mine. Now I can part my old battery out on eBay

JeffD

 

I didn't notice the fan running, but it was in cold weather.

JeffD

 

It helps when you have a long term relationship. I've trained them in Prius maintenance for 7 years.

• 3 ATF refreshes - They questioned the need at first
• Coolant refreshes twice (Water Pumps at 150k miles)
• Plugs & PCV at 100k
• Upper Steering column assembly repair at 150k

JeffD

 

I have had a long relationship with this dealer in CT (A1Toyota - 2 hours from you, talk to the service manager) and they may do it for others as the experience was good.

Re-InVolt gives a 12 month/Unlimited mileage warranty (same as Toyota). The dealer just did the installation and checked it out before delivery.

There are some useful shops around the country that can get a Prius with a HV battery problem back on the road for less than a dealers $3k+. Ones that I know of are in CA (Arts Auto, Luscious Garage), North Florida (Forgot the name, do a search), Indianapolis (AutoBeYours) and, of course, NC (Re-InVolt).

I also noticed a "Hybrid Certified" repair station just northeast of Harvard when I used to drive to my son's apartment. Check around.

JeffD