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Requesting suggestions about how to proceed with 2006 Prius with HV battery issues

Discussion in 'Gen 2 Prius Main Forum' started by dctrip, Dec 2, 2018.

  1. dctrip

    dctrip New Member

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    Hello everybody,

    I've been reading this forum for years and have finally reached the point of needing some advice myself.

    My wife and I bought a 2006 Prius (package 1, I believe) new in 2006 and it generally served her well for roughly 120,000 miles, though the hills in Seattle have probably kept us from getting optimal fuel economy. (We probably topped out at about 47 MPG, and typically got closer to 40-42.) For a variety of reasons, we bought her a new Highlander about a year ago.

    Shortly after we bought the Highander, the Prius, which we were (stupidly, it turns out) planning to sell privately rather than taking a financial hit on the lower trade-in value, started throwing the dreaded P0A80 code. Eventually, it also threw a specific battery block error code (P3019), and after getting a quote of $3,300 to replace the whole battery pack, we had a decision to make.

    At that point, we didn't really think we could get decent return selling the Prius with a bad HV battery, but we also didn't want to pay for the replacement only to turn around and sell the car for maybe only $1,000 more than the repair cost. Because the car that I've been driving (a 2006 Scion xB, since I don't mind driving a toaster on wheels) gets roughly equivalent mileage to the Highlander, we figured that selling the Scion and fixing and keeping the higher-MPG Prius for in-city driving made sense.

    I still was squeamish about the $3,300 battery replacement cost, so I started reading online (here and elsewhere) about various other options, and eventually we settled on changing out the single bad cell. We finished that work around May, and the car had performed reasonably well (if only getting around 30-35 MPG) until October, when it started (unsurprisingly) throwing P0A80 again. After clearing that code with Torque Pro a couple of times, I eventually got a specific battery block code (but different from the one earlier this year). I had to get the car home in limp mode soon thereafter, and haven't driven it since. Luckily, I hadn't managed to sell the Scion in the meantime, so I'm driving that while I figure out our new plan.

    All of that background leads to these questions, which I'm hoping will elicit opinions and suggestions from some of you:
    • If we do still go the battery replacement route with the Prius, does anybody know of a dealer in the Seattle area who sells a new OEM Toyota pack for the under-$2000 prices I've seen mentioned in other threads? I'm comfortable doing the labor myself (having been through the replacement process once already), but I've looked at pretty much every dealer's site in the state and haven't found a good price, though there are a few dealerships for which I haven't sent in the quote form. Toyota of Seattle quoted me around $2,600 for the part uninstalled (after core deposit return).
    • Are the packs sold by Toyota recently manufactured cells, or were they manufactured years ago only to sit around around since then (and would that diminish their performance)?
    • I know better than to buy a reconditioned pack based on what I've read here, but is there a consensus on the packs sold by NewPriusBatteries?
    • I've been reading up on other high-cost issues that could crop up in the post-100,000 range, and it seems like the most common one would be a transmission issue. Is there any way to predict that (by checking the current fluid state, maybe), or is it more of a luck-of-the-draw thing? Would driving on an atypical number of hills (again, this is Seattle) tend to cause more failures?
    • If we do decide to sell the Prius in its current state, is there any sort of a market for it? Or would we be better off donating it to a charity (maybe a school auto shop program? do those even still exist?) and getting at least some kind of deduction out of it?
    I think that's everything. I very much appreciate all of the contributors to this forum, and would greatly appreciate any suggestions or answers you're willing to give. I only wish that I had some amount of expertise that I could have lent myself over the years. For whatever it's worth, this is definitely one of the better car-based communities that I've seen over the years.

    Thanks!
     
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  2. Raytheeagle

    Raytheeagle Senior Member

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    Welcome to Prius Chat (y).

    If comfortable with repairing the hv battery, I’d go for the toaster kit:

    NewPriusBatteries.com | Home

    You’ll be good for a long time and get some more mileage out of the 06 with only 120 k miles:).

    That’s what I’d do(y).
     
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  3. jerrymildred

    jerrymildred Senior Member

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    I'd be pretty surprised if you found one from a dealer for less than that $2,600 you found. But you might get lucky. The new batteries from the dealers use all new cells.

    Another option is getting a 2-3 year old battery (not a rebuild) from a wreck. There's a guy here in Tampa who specializes in hybrids who sells them, so there might be someone like him up your way.

    But, actually, the kit @Raytheeagle mentioned is probably the best bang for the buck if he has them in stock.

    A more likely second issue than the transaxle would be the brake accumulator pump. The transaxle is expensive, but failures, while not unknown, are pretty rare from what I've read here and heard from my hybrid specialist friend. Inverters can also fail and that ain't cheap either. But at only 120,000 miles, you should be safe for quite a while.
     
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  4. 2k1Toaster

    2k1Toaster Brand New Prius Batteries

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    They are indeed in stock!
     
  5. Raytheeagle

    Raytheeagle Senior Member

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    How much stock do you have these days:whistle:?

    I know the current shipping challenges have hindered inventory :cool:.

    Good to hear that is improving (y).
     
  6. SFO

    SFO Senior Member

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    The previous owner of my vehicle liked to drive hard and fast, and he was able to pop the transmission at 110k (while driving up the Sierras on hwy 50). Alas, he had never changed out the fluid. Would've changing the fluid once or twice before 100k prevented such? Hard to say, though one might argue it wouldn't have made a difference given his driving style and that particular long uphill drive.

    If you've never drained and filled the transmission fluid before, then now would be the time and its not that difficult or expensive.

    You might have luck finding a better price on new battery in Oregon, and you could save a little on the sales tax.

    Another option might be Hybrid Car Battery Repair & Replacement | Hometown Hybrids or @Hometown Hybrids
     
    #6 SFO, Dec 2, 2018
    Last edited: Dec 2, 2018
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  7. 2k1Toaster

    2k1Toaster Brand New Prius Batteries

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    I try to keep 20-30 minimum in stock nowadays. :)
     
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  8. 05PreeUs

    05PreeUs Senior Member

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    1) While OEM batteries are good, there are lower-cost replacements that are "as good".
    2) I am pretty sure the OEM HV modules are NEW, just the cases, wiring, interconnects and "computers" are re-used/re-built/re-conditioned
    3) YES - NewPriusBatteries!
    4) Condition, Condition and maintenance. If it is in good or better condition and has had ALL of the Toyota reccomended maintenance and you like the car, FIX IT.
    5) No, lucky to get $1k for a non-running G2, although there are more than $1k worth of HV modules in it, even at "core" price. :shrug:
     
  9. PriusCamper

    PriusCamper Senior Member

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    Hi @dctrip, I'm an hour south of you and would be willing to help if you want to talk more on the phone or private message. In general, Prius that are sold on the cheap with bad batteries sell super fast, so fast you rarely see them because those who know how to repair battery packs snap 'em up real quick.

    The main battery pack repair person in the area is down by the airport in Burien and is on Craigslist selling rebuilt packs with a warranty, which I'm pretty sure is the most common way people with bad batteries repair before selling.

    The Toyota dealer down here in Tumwater quoted me a brand new set of battery modules for ~$1900 once you return your core. You could probably get the same price in Oregon without sales tax to save a little bit more. An experienced person could swap out the modules in few hours and add a few more hours to that if you have basic mechanical skills but it's new to you.

    Myself and my friends, work on repairing these packs occasionally and would also be happy to make you a deal for the car as is, or work on your pack while you use a loaner pack if you want the least expensive fix.

    The primary issue with getting a year(s) out of a repaired pack is how thorough you are with repair and reconditioning. As you mentioned you did swap out a module, which got you through the Summer, which is a good sign of the health of the pack overall because hot weather is brutal on these things when they get old. But key to swapping out a module is reconditioning all remaining modules, which massively improves their capacity, as well as gives you data on which modules will likely fail next so you aren't in the position you're currently in.

    Being thorough in rebuilding packs is a time consuming endeavor, but usually the least expensive solution... Of course if you're ready to sell and want a max warranty a new pack is good for a one year warranty if you install yourself ($2K) and three years if Toyota installs it (closer to $3K)

    Anyways, I'm near by so get in touch if you need help or want to discuss further options...
     
    #9 PriusCamper, Dec 3, 2018
    Last edited: Dec 3, 2018
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  10. Nyfan

    Nyfan Junior Member

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    Hey everyone
    I also have a 2006 Toyota Prius with 210.000
    miles. The cars Hybrid battery is dead. I tried a few local places but they were over $1500 for reconditioned battery with a 6 month warranty. Plus now that the car has been sitting for 6 months the small battery has died. So I can’t even get into the car. Tried using the key in the key fob but I can’t get it to turn. Does anyone know of a mobile repair service that would come to Las Vegas? Should I just tow to a dealership to sell it as is. Was running great before this mess with the batteries.
     
  11. PriusCamper

    PriusCamper Senior Member

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    There's 28 modules in your hybrid battery pack... Each module can be purchased online in a refurbished condition for $30. But if you just swap a module and don't recondition the remaining modules you won't be certain that you got all the bad modules out of the pack and the modules might not match, which means more warning lights on the dash.

    A thorough reconditioning of all modules will likely point out the next ones likely to fail so you can replace them. Catch is quality servicing of a bad battery pack is very labor intensive, upwards of 20+ hours if it's done right. So trick is to find someone who is charging $1500 for quality work and not just profiting off of a quick fix.

    Alternatively if you or a friend want to pull the pack yourself and do this work, you'll only have spend $30 bucks a piece on the modules and $100 on some charging and discharging gear, but it takes time to learn about it all and do the work correctly... Let us know how we can help you further?
     
  12. jerrymildred

    jerrymildred Senior Member

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    Well, problem #1 is getting the doors open so you can work on it. If the mechanical key won't work, your cheapest option is probably a locksmith. And then getting the key to work if it's the right one or getting the right one if you bought the car used and the seller gave you the wrong key.

    Next is getting the car running. Once you get the doors open, you can crawl into the back and release the hatch from inside. That's explained in the manual, so I won't repeat it.

    12V might survive if you put it on a charger, but getting that low will have shortened its life expectancy and might have killed it outright.

    As to the 500 pound gorilla in the corner, I don't recommend a rebuilt battery. They almost always amount to buying expensive problems because they don't last very long. For a car as old as yours, a two or three year old HV battery from a wreck should get the best bang for the buck. But new batteries have come way down in price so that's another option, especially if the car is otherwise in great shape. And, if you're a reasonably competent diy, it's not hard to change it yourself. More work, but save a bunch of money.

    Edit to add: I just found this great how-to: A Chris Fix YouTube Video | PriusChat
     
    #12 jerrymildred, Dec 12, 2018
    Last edited: Dec 12, 2018
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  13. Skibob

    Skibob Senior Member

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    Odd how the key won’t work. With zero use those things should always work. Do you have another fob with the key? Spray some WD40 in the lock cylinder, and try that one. How are your mechanical skills? Could you do any type of traction battery work yourself?
     
  14. frodoz737

    frodoz737 Top Wrench

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    @dctrip. FWIW...Even with only 120,000 miles on the meter, it's still a 12 year old Gen II Prius with a bad HV battery. You could repair/replace the battery for anywhere between $1,800 and $5,000 depending on your mechanical ability or agility to grab your ankles, but even then, the car will not sell for $3,000...and trade in for even less. I say donate it to the local public high school auto shop. You still have two vehicles, you make room in the garage (or what ever space it's currently taking up), you get a tax write off and get to feel good about helping students with their future careers. YMMV
     
    #14 frodoz737, Dec 12, 2018
    Last edited: Dec 13, 2018
  15. JC91006

    JC91006 Senior Member

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    Spray some lubricant in the key hole and then try the key again. You can try wiggling it a bit when you're turning.
     
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  16. golfmk681

    golfmk681 Active Member

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    Gosh if the Prius is mechanically sound and I’d keep the Prius and upgrade the battery to a newer pack. They’re great cars and keep on going. I just past 276,000 miles on mine. I think if you know the car and the transmission and engine are good you could have another few years of service on the car if you changed the battery. You can potentially equal the cost of the battery in 10 months of a new car payment.
     
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  17. JC91006

    JC91006 Senior Member

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    Did you find out what was the knocking sound in your engine?
     
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  18. golfmk681

    golfmk681 Active Member

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    Coil pack failed lol. Still burns about 1 qt ever 5k miles but it’s fine. I’m ok with the oil loss. I’ll do an engine swap if I ever needs another engine. I love pilling on the miles and not giving a fuccccc lol. I pulled 20k miles in 9 months!!! I just got the car detailed inside and it doesn’t have a funk anymore lol.
     
  19. Prodigyplace

    Prodigyplace Senior Member

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    Less than $1800. @2k1Toaster pack is $1600 shipped and then you can sell any good old modules to recoup part of that.
     
  20. Hamptgx

    Hamptgx Member

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    Couldn't get my key to turn either, spray some WD40 in lock and on key and work it back and forth (don't force it) it will free up.