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P3000-123 and P0A80 after hybrid battery reconditioning and rebalancing

Discussion in 'Gen 2 Prius Technical Discussion' started by bbellgrl, Sep 3, 2024.

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  1. bbellgrl

    bbellgrl New Member

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    Many thanks. just ordered 2 new modules. will update when they have been replaced and reinstalled.
     
    #21 bbellgrl, Sep 10, 2024 at 3:33 AM
  2. mr_guy_mann

    mr_guy_mann Senior Member

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    Good luck. There are MANY posts about replacing modules in the HV pack and discharge - charge cycling.

    In general it seems that "just" putting a few modules in seldom works as the installed ones do not match the condition of the others. Maybe 10-15% success - ie the lights stay out for 6-12 months.

    As the battery is used, the effective module capacity degrades. As long as they degrade by the same amount, the pack will work ok.

    The "new" modules likely do not have the same (effective) capacity or State Of Charge. That means that during use the voltage difference (delta) will be high and often flags P0A80 again.

    Since the replacement modules often are in "better" condition than most of the old pack, another block is now the lowest voltage and that one sets the code.

    Replace that block and then the next one becomes "the lowest" and repeat. We call this game "whack a mole".

    If you work on the pack, pay attention to safety procedures, use a torque wrench to tighten HV stud-nut connections to 48 INCH-pounds, and do all 3 steps when refitting the orange HV service plug.


    Posted via the PriusChat mobile app.
     
    #22 mr_guy_mann, Sep 10, 2024 at 1:15 PM
  3. bbellgrl

    bbellgrl New Member

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    2008 Prius
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    Thanks for this. Great points I hadn't thought of. Already ordered the two modules, so we'll see how this goes. When I reconditioned all the modules (it took almost 2 months), just about every module was reporting great numbers after several cycles, so I'm hopeful they'll be strong enough to keep the warning lights off for some time. If they come back on, I'll likely just order a new pack.

    Can you remind me what the 3 steps are for the orange HV service plug? I want to be sure I haven't been leaving anything out.

    Thank you again.
     
    #23 bbellgrl, Sep 10, 2024 at 2:55 PM
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