2012 Prius V: SOC Dropping Intermittently And Instantly And Throwing P0A80 Code

2012 Prius v, 209k miles

Last year I replaced two hybrid battery blocks that failed. Two months ago I replaced two more hybrid battery blocks that went bad. I also replaced the voltage sensing harness and primary ground cable because of corrosion. Things have been working well and suddenly, 1,500 miles later, this has started.

Yesterday, cranked up and turned on Dr. Prius. SOC was 58%. I pulled out of the driveway and suddenly the dash lights lit up and my SOC dropped to 27%. It was showing an active P0A80 code. I cleared the code and things started working. About 30 minutes later, it did the same thing.

Today while driving we stopped for about 20 minutes. Dr Prius was showing the SOC at 70%. As I pulled out, the dash lit up and my SOC dropped to 27%. I cleared the code and things started charging. This time the Delta SOC (red) started increasing as we were driving. You can see where I cleared it.

Later I hooked up my Techstream. All block voltages were fine. SOC was 56%. Suddenly, it threw another P0A80 code and my SOC dropped to 26%. Block battery voltages dropped down into the 15 volt range, but there were no significant differences between the voltages.

I am at a complete loss as to what to check next. We're leaving in 6 weeks for a 6,000 mile trip...and I can't leave home like this! Video link attached.

Any input or suggestions would be appreciated.

Thanks!

 

Brian,
Thanks. I will hook techstream back up and try to find that data. I have never looked at/for freeze frame data before...hopefully I can find it! I'll update afterwards. Thanks again!

 

OK, I pulled the freeze frame data related to the P0A80 Code. At this point I am counting on the great minds here to analyze this...because I don't have a clue! I did note that all the block voltages looked OK (to me). Thanks!

 

Yes, I had cleared the last P0A80 code because we were driving and power to the wheels was very low. When I did the sensing wire replacement I did use a used harness that was corrosion free. I also had to replace the sensor module (below is a link to that post with pictures. It was so bad the board in the module was corroded. I have also rebuilt the primary hybrid ground cable that runs from pack 1 and plugs into "something" at the end of the batteries (next to the sensor module). At this point, I would like to replace that cable as well. I am certain all the battery nuts are tight as I had went over them twice.

We live on the Gulf Coast, on the water, so humidity and high temps are the norm. Last year I was checking the spare tire (just an air pressure check) and found about 6" of nasty water around the tire. Everything down there was wet...and I guess that moisture would have also got into the battery. Could be why I've had such a corrosion problem. I did find the source of the leak so we are now remaining dry.

The ground cable (since I don't have things opened up yet); does it plug into the battery ECU? I will start searching for a ground cable and ECU.

Please know how much I appreciate your help.

Link to my previous post:
P0AFC... Terrible Wire and Voltage Module Corrosion | PriusChat

 

Brian,
The battery ECU...is that the part with the relays on it?

Would this be it?
10-15 TOYOTA PRIUS BATTERY ECU RELAY CONTACTOR VOLTAGE SENSOR 89892-47020 MODULE | eBay