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Second gen to third gen battery conversion

Discussion in 'Gen 2 Prius Technical Discussion' started by Wrecit, Apr 11, 2021.

  1. Wrecit

    Wrecit Active Member

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    Maybe I am just to dumb to use site search correctly but can not find detailed info so asking here.

    Have read several places about putting a 3rd gen battery in a second gen and there is a local shop saying he will do the swap for 850 (700 for third gen battery 150 install)

    Is there a web site or thread here that has detailed instructions or any youtube videos you can direct me to for info. I am very mechanically inclined and want to see if this would be something I can tackle
     
  2. Rmay635703

    Rmay635703 Senior Member

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    Usually it’s a cell swap from a gen 3 to gen 2

     
  3. PriusCamper

    PriusCamper Senior Member

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    With experience you can swap a Gen3 stack of modules on to a a gen2 chassis in less than two hours. Very straightforward simple work. WIth removal and installation of pack taking another hour. Maybe double that time the first time you do it.

    Main thing here is what the date of manufacture serial numbers on modules say... If they all match up the pack is original and will last a long time. If they don't match up and pack has been rebuilt then 3months to 3 years before pack fails again.

    Also Gen3 motors are much harder on their battery packs... And newer is always better when it comes to modules, but I've seen Gen3 packs go from the best pack in my collection to the worst pack and suspect that's because it lived a much harder early part of its life in a Gen3.

    So same rules apply for used cars, which is buying a pack from the little old lady that went to the grocery store and church once a week will always provide better quality than buying from a family with lots of teenagers who lost their driving privileges.
     
  4. sam spade 2

    sam spade 2 Senior Member

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    BUT......the entire Gen 3 pack will not fit directly into a Gen 2 vehicle......right ??
    Which is what the OP seems to think is going to happen.
     
  5. T1 Terry

    T1 Terry Active Member

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    I'll show my ignorance here, what is the difference between a Gen 2 traction battery and a Gen 3 traction battery? I was lead to believe they are both nom. 201v, 28 modules of 6 cells per module, so a total of 168 cells. Each cell is nom. 1.2v to give the nom. battery voltage of 201.6v. The voltage range for a nickel-metal hydride cell is reported to be between 1v at the lower end and 1.5v at the upper end.

    My Gen 2 Prius has a scan gauge fitted and the lowest I've seen is 198v and the highest 240v, although when the old traction battery was about to pass on I did see 280v a few times.

    So, 168 * 1.5v = 252v, so what is the maximum voltage the traction battery can be without causing the computer to flip out or damage the inverter?
    Could I build a higher voltage traction battery using LTO cells with a greater capacity and do away with the original traction battery completely?

    T1 Terry
     
  6. PriusCamper

    PriusCamper Senior Member

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    all the same, just slightly different ECU, fan location and mounting system.