I just bought a brand new hybrid battery from Toyota for my 2007 Prius and in the process of installing the large orange wire harness onto the battery, I over tightened one of the nuts and sheared off a stud on one of the cells. Would there be any issues installing a single reconditioned cells in place of the damaged unused new cell? Does Toyota sell individual cells new?
Ouch. Toyota doesn't sell individual modules. You could put in a reconditioned module, but unless it is very close to new in performance, it will be the limiting factor in the performance of the whole pack. If you haven't bought a good-quality inch-pound torque wrench, it's good to have for this job.
Would you advise on installing the reconditioned module in the same spot as the current damaged one or towards the front for easier access in the future? Right now I have to remove 18 of the modules to get to the 19th one.
You will find brand new factory modules at eBay. Yes, a torque wrench is a very wise "must have". Pictured tool is what I purchased when I replaced my hybrid pack.
Damn, you folks torque them? I just replace the terminal plates, and set my Bosch IDH182 impact on the lowest setting and give it one "dugga". I've rebuilt three batteries this way. I feel like I might be a heathen.
Brand New OEM Toyota Prius Hybrid Battery Cell NiMH 2004 2005 2006 2007 2008 | eBay NEW Original Toyota Prius Hybrid Battery Module 2010 - 2015 | eBay
I have seen in the past new oem modules for half the above prices. On to another subject. I was curious if a broken stud could be professionally repaired, so I took apart a bad module. There does not appear to be enough metal to drill and tap for a new stud.
As expected. not sold by Toyota. They also mention Gen 4 modules. Only the lowest trim Gen 4 had compatible batteries. Other trims used Li-Ion modules.
If I could sell new modules for $175 each, I would be happy to buy dozens of new HV batteries, break them down and sell individual modules. One 28 module pack = $4900, that's a pretty good margin. Or buy a Camry pack, use 28 to rebuild your pack and sell the rest. Plenty of options actually, but I just don't know there would be high demand for individual 'new' modules. A new module in an old pack is a recipe for problems.
The AWDe Gen 4 Prii use NiMH modules, not the newer Li-Ion ones. You could take that module to a machinist to find a solution. JeffD
