Mix Gen2 and Gen4 HV Battery Cells?

I'm generally the whole pack kind of guy seriously it's just easier to deal with it that way or if you know a rebuilder that has the good equipment and is really qualified to do this work and knows what they're doing like this guy at the hybrid doctor up in Fairfax Virginia He sells on eBay too so far so good with him I've had some very good luck with his rebuilt built whatever batteries He seems to do a very good job He seems to be in it to win it in the EV electric pack game He goes to all the shows and all the classes and whatever the heck so far so good.

 

Your original modules (not cells) are getting older. They are more likely to fail sooner if you add newer and new modules.

Your best option is to try and find a reasonably new Gen 4 (NiMH) battery pack from a wreck, swap all 28 modules and be done with it.

 

About 4 years ago I bought a 2010 Prius solar roof JBL car from the time I bought it from the place drove it home woke up and drove it the next day lights were on all kinds of funny business was going on I looked at the hybrid battery in the trunk it was all frosted nuts and dark bus bars and the whole nine. I went to a friend of mine's place called Wagner's Auto salvage in Durham by the 2015 battery from another Prius that was still in the car on the lot at the junkyard not in water car still sealed up and closed I installed that battery in my 2010 solar roof car I got it for $400 with exchange of my old one I left out of there with it put it in the 2010 with the solar roof it ran great with no lights but it still had a PO a880 code I think the one that's bad battery It's not had the light on but it's been stored in the memory the whole time I've had this battery it will not clear it will not put the light on looking in TIS or Dr Prius nothing looks really wrong car still runs great though and I'm not going to change it until something fails goes wrong or maybe lights the light and becomes a hard code I guess so. It must be a soft code?..

 

My serious question would be are you refurbishing ,ie, charging/ discharging all the 28 cells to.proper specs and then finalizing by balancing all the cells in the pack together? This would be after you replaced bad cells first with good cells irregardless what generation cells your using and or mixing together. Sounds like your just replacing bad cells sticking in good cells without properly recharging the entire pack together which then need to be balanced all together. If this is the case you will continue to have problems. When doing a hybrid battery rebuild attempting to correct a P0A80 / red triangle code to make the hybrid battery last there needs to be a proper charging/discharging of all the cells which requires the use of specific equipment and then balancing the entire pack before reinstallation of the hybrid battery.