1. Attachments are working again! Check out this thread for more details and to report any other bugs.

How to repair cracked housing on inverter connector?

Discussion in 'Gen 2 Prius Main Forum' started by tga, Dec 2, 2011.

  1. tga

    tga New Member

    Joined:
    Dec 2, 2011
    4
    0
    0
    Location:
    Cupertino, Ca
    Vehicle:
    2009 Prius
    Model:
    V
    Hi All,

    I have a salvaged 2009 prius. I just found out from my dealer that the connector between the a/c compressor and the synergy drive inverter is cracked and falling apart so it's causing a short. You can't just change the connector so the bill to replace the a/c compressor and the inverter comes to about $6700 and it's not under warranty because it's salvaged.

    I come on this forum to find if there's ways for me to just replace the connector and where I might be able to find such a thing. The other thought I have is to just find some way to create an insulated housing for the existing connector. Maybe use a plastic mold?

    What do you all think? What's the best way to go? The connector basically has two parts. One part is attached to the a/c compressor and the other part is attached to the inverter and then you just connect them together as if it's a power extension cable. It's orange in color.

    Thanks All!
     
    #1 tga, Dec 2, 2011
  2. efusco

    efusco Moderator Emeritus
    Staff Member

    Joined:
    Nov 26, 2003
    19,891
    1,192
    9
    Location:
    Nixa, MO
    Vehicle:
    2004 Prius
    Model:
    N/A
    I think the best/safest way to go is to look for a salvage inverter. May still be costly, but this does not, to me, seem like a good item to try to do a "duct tape" repair on!

    Perhaps someone else can chime in if the connector alone can be replaced--do you have a photo or part number for the item you're talking about?
     
    #2 efusco, Dec 2, 2011
  3. seilerts

    seilerts Battery Curmudgeon

    Joined:
    Mar 7, 2010
    3,326
    1,512
    38
    Location:
    Santa Fe, NM
    Vehicle:
    2005 Prius
    Give Lech Auto AC a call -- San Mateo. He is the Bay Area expert on the Prius A/C system.

    (650) 343-2975

    If he can't fix it, he may refer you to Luscious Garage. I strongly suggest that you let experts figure this out, as a DIY repair is potentially fatal.

    EDIT: Another reason to see Lech is that, if your connectors were broken, then the shop doing the repair probably botched the A/C charge as well. You could spend a goodly amount fixing the connectors only to have the compressor bomb out next summer.
     
    #3 seilerts, Dec 2, 2011
  4. tga

    tga New Member

    Joined:
    Dec 2, 2011
    4
    0
    0
    Location:
    Cupertino, Ca
    Vehicle:
    2009 Prius
    Model:
    V
    Here's a picture of the inverter. The orange thing on the bottom is the connector. The connector's metal contacts are actually fine. It's the orange plastic housing that's cracked and falling apart. Looking at this picture, you can't see the metal contacts but on my prius, you can.
     

    Attached Files:

    #4 tga, Dec 2, 2011
  5. kohnen

    kohnen Grumpy, Cranky Senior Member

    Joined:
    Jun 13, 2007
    317
    57
    0
    Location:
    Fullerton CA
    Vehicle:
    2007 Prius
    You could always look for conventional 3 phase 480 Volt connectors and then wire them up yourself. It would be non-standard, but would work.

    Of course, you MUST take reasonable safety precautions (disconnect the main battery by removing its orange plug) before doing this sort of work. Don't take the advice of some idiot on the internet and end up killing yourself!

    You could just remove the connectors, splice the wires and cover it using copious amounts of heat shrink tubing (with built-in waterproofing melting goo).

    This way would be cheaper, but would be more work if you ever have to replace the inverter or the compressor.
     
    #5 kohnen, Dec 2, 2011
  6. tga

    tga New Member

    Joined:
    Dec 2, 2011
    4
    0
    0
    Location:
    Cupertino, Ca
    Vehicle:
    2009 Prius
    Model:
    V
    Thank you. That's exactly what I'm hoping for. I want to get some references to good tech who can help me fix it. The couple of shops I've called so far and the dealer say they don't want to do patch work which I understand but this is somewhat of a special situation. None of the other components were replaced during the crash. Most of the fix for the salvage was only the frame and panels. The dealer say most likely the connector was cracked and the people fixing it just didn't see it but now after wear and tear, it broke apart.

    Any other good references I should check out, please keep them coming.

    Thanks!
     
    #6 tga, Dec 2, 2011
  7. seilerts

    seilerts Battery Curmudgeon

    Joined:
    Mar 7, 2010
    3,326
    1,512
    38
    Location:
    Santa Fe, NM
    Vehicle:
    2005 Prius
    I don't know offhand if the connector can be simply repaired. Lech would know because he sees salvage rebuilds all the time. Definitely, if you can see metal, that's really bad.

    An option is to call around and get an inverter core. Many times, the case will crack in a collision, but most components are still good, such as your cable. This could be fairly cheap. If you can transfer the connectors, then it is easy. Otherwise, you would need to pull the inverter, take out the old cable, and put in the new one. See attached.
     

    Attached Files:

    #7 seilerts, Dec 2, 2011
  8. jdcollins5

    jdcollins5 Senior Member

    Joined:
    Aug 30, 2009
    5,131
    1,338
    0
    Location:
    Wilmington, NC
    Vehicle:
    2010 Prius
    Model:
    III
    All electrical connectors can be replaced if you have the correct pin extraction tools that match the connector and a replacement connector part.

    The question is whether the hybrid shop will have the correct equipment. If the shop is the Prius AC expert my guess would be that they would have the correct equipment. The cost to replace the connector should be minimal compared to an inverter/converter.
     
    #8 jdcollins5, Dec 2, 2011
  9. tga

    tga New Member

    Joined:
    Dec 2, 2011
    4
    0
    0
    Location:
    Cupertino, Ca
    Vehicle:
    2009 Prius
    Model:
    V
    I tried giving Lech Auto A/C a call this AM but it's been disconnected. Do you have a more updated number for him? I looked on the web but the search turned up the same number as the number you have.

    Does anyone in the bay area have a good guy to recommend?

    Thanks.
     
    #9 tga, Dec 2, 2011
  10. seilerts

    seilerts Battery Curmudgeon

    Joined:
    Mar 7, 2010
    3,326
    1,512
    38
    Location:
    Santa Fe, NM
    Vehicle:
    2005 Prius
    huh...I see he hasn't posted for a while. Hope he's doing all right. You can PM/email him here: PriusChat Forums - View Profile: lech auto air conditionin

    Luscious Garage and Art's Automotive would be my top two picks for shops to help you with this. Luscious should have Lech's contact info as well since they sub him jobs.
     
    #10 seilerts, Dec 2, 2011
  11. drees

    drees Senior Member

    Joined:
    Oct 31, 2007
    1,782
    247
    0
    Location:
    San Diego, CA
    Vehicle:
    2008 Prius
    Definitely call up Luscious Garage - they can fix anything that breaks on a Prius and likely have the parts on hand needed to fix your inverter issue. Check out their blog - has details on all kinds of repairs. They're up in the city so it's a bit of a drive, but I've never heard a bad thing about them.
     
    #11 drees, Dec 2, 2011
  12. El_jai

    El_jai New Member

    Joined:
    Dec 13, 2023
    2
    0
    0
    Location:
    San Antonio
    Vehicle:
    2004 Prius
    Model:
    Base
    Bumping this, my inverter went out so I bought one off FB-Marketplace, but didn't notice this connector was damaged until I got it home. Can these be swapped out? My Prius guys said he doesn't do that for liabliity.
     
    #12 El_jai, Dec 13, 2023
  13. El_jai

    El_jai New Member

    Joined:
    Dec 13, 2023
    2
    0
    0
    Location:
    San Antonio
    Vehicle:
    2004 Prius
    Model:
    Base
    Does anyone know the p/n for this 3 wire duetch connector? (On inverter side of the ac compressor).
     
    #13 El_jai, Dec 14, 2023
(You must log in or sign up to post here.)