I'm hoping for advice on what hybrid battery cables to replace on my 2008 Prius after I noticed that the bus bars were corroded. The cables on each side of the battery have corrosion that extends from the connector to underneath the cable sheath. It's been difficult to find the correct new ones One of the cables I want to replace is marked G9240-47020A, but I can't find it new. Perhaps it's been replaced by a newer model? Here's a list of parts I've found but because there are no pictures I'm not sure what to buy. Wire, Frame, No. 2 Product ID: 82165-47040 Hybrid Battery Wire Harness G3830-52010A (can only find on eBay, used, but the picture looks exactly like the one I want to replace) Plug Assembly Electric Product ID: G3830-47061 Plug Assembly Electric Product ID: G3830-33011 Plug Assembly Electric Product ID: G3830-47050 Plug Assembly Electric Product ID: G3830-42031 Cable Main Battery Part Number G9242-47090 Any advice is much appreciated.
Now that I'm able to post links and photos, this wire harness in particular is what I'm hoping to buy new: Hybrid Battery Wire Harness G3830-52010A I can only find it used on ebay. Where can I obtain it in new condition?
Use Amayama for 2008 Prius marked green in diagram. https://www.amayama.com/en/part/toyota/g924247090
I built my own cables, it was easy. I purchased the cable from Lowes. I removed the end connectors on the old cable with a Dremel like tool. Cleaned up all the corrosion with vinegar and a wire wheel on the end pieces. Soldered the end pieces to the cable, making sure I had everything the right length and correct position. Some of the old cables only had corrosion for a few inches so I cut out the corroded wire and spliced in the new cable by soldering the ends together. I used heat shrink to cover all the soldered connections
Just be careful. Soldering is not preferred as a safe way to terminate cables in a vehicle because of the ongoing vibration. I used to solder sound system connections because I thought they were stronger. They aren't. Soldering is not recommended for heavy-gauge battery cables in cars because: Soldered joints can become brittle and are prone to failure under vibration or thermal cycling. Solder can wick up the cable, making it stiff and more likely to break. Excessive heat during soldering can damage insulation or nearby components, and improper technique can result in a weak or unreliable connection. Soldered connections are more susceptible to corrosion if not properly sealed.
FYI, Toyota is still stocking G9242-47090, the main battery cable on the side with the sense harness for about $40 and the sense harness appears to be 82165-47040 for about $90. For gen2
