Hybrid battery refresh gone wrong, jumping SOC, codes,12v=0v

Discussion in 'Gen 2 Prius Care, Maintenance and Troubleshooting' started by EricGroce, Aug 6, 2025 at 11:38 AM.

  1. EricGroce

    EricGroce Junior Member

    Joined:
    Feb 2, 2021
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    Location:
    Independence, MO
    Vehicle:
    2007 Prius
    Model:
    N/A
    So I'm very familiar with batteries I rebuilt three Gen 2 Prius batteries over the years and always had wonderful results.. most recent one lasted a solid 90,000 miles on its refresh with used cells

    Anyway I'm running into a problem where I'm getting p3000 and p0a80

    Now I can reset the codes and they're fine as long as I don't run the battery down to a really low state of charge and then demand a lot from it

    Additionally I'm noticing that if I decelerate off the highway I will see as much as 94% state of charge on Dr Prius... And it will jump down to the lower 30s as well

    Then I may see it report between 30 and 40% state of charge but it's packed voltage be up in the 250s... This makes no sense

    Additionally after the swap I'm now getting a report of zero volts on the 12 volt battery.. of course my multimeter tells me that is completely inaccurate, at rest with the vehicle off I see about 12.5 volts, and with the car running somewhere between 14 and 14.2

    I suspect that there is an issue with one of the connections on one of the cells or possibly even a bad cell

    This also doesn't make a whole lot of sense because I did this the exact same way I've done them before, I rack all the cells into a pack and apply normal compression.. then I use an RC car charger to discharge and charge several times, this unit keeps track of how much capacity is going in and then how much is going out and gives you a report...

    All of these cells were at minimum 5000 mAh, additionally these cells came out of a gen 3 and have been transplanted into a Gen 2 battery shell

    I cleaned all the connections

    The only thing that I did different this time, normally the sensor wires will be connected directly to the battery terminal and then the bus bars go over the terminal

    But to me that doesn't make sense for current flow, so instead I changed this and it's now attached terminal to busbar, sensor wire on top of the bus bar

    Could this be potentially my problem?

    Additionally I am noticing that block number 11 shows particularly low, a few tenths of a volt lower than the rest of the blocks

    Oddly, yesterday when I first drove it about 20 miles, the codes would show up whenever I would get down to one bar, such as idling with the air conditioner on... The codes of course would clear and everything would be fine

    Also, yesterday Dr Prius was reporting between 14 and 14.2 volts on the 12 volt battery, but today it's zero, how does it even start if it's zero?
     

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