Is the hybrid battery really failing?

To first answer your question about modules vs. batteries: “module” is a term coined by Toyota to reduce confusion when talking about these small modular batteries versus the large hybrid vehicle battery in the same space. Technically, a module is a battery. It consists of six cells in a sealed container. In multiples, these small batteries (modules) are used to make up a larger battery (the hybrid vehicle (HV) battery), suitable for whichever car it will be used in. This modular design (hence the name module) gives Toyota the flexibility to build batteries of different sizes. I hope this explanation helps clarify the terminology.

This leads into why the pricing looks the way it does. The only battery that contains brand‑new (OEM) modules is the one supplied by Toyota as a new HV battery. Even then, it comes with a bit of “some assembly required”: everything to the right of the electronics bay comes fully assembled and ready to install, but the components in the electronics bay itself (ECUs, contactors, current sensor, etc.) are reused from your original pack and swapped over to the new battery. Everything else you find on the market is some kind of variation on:

• Recycling old Toyota modules, or
• Using battery modules that are new but sourced from China (usually).

This isn’t automatically a reason to dismiss them, but so far, these new third‑party modules have not shown anything close to the same longevity as those from Toyota. That’s a big part of why “modules only” listings are cheaper than a complete new Toyota battery.

Offerings from various suppliers of secondhand batteries vary greatly. These can be anything from:

1. A completely assembled HV battery that can be quickly swapped in, or
2. A set of reconditioned and balanced modules that you have to swap into your existing battery case.

The second option is usually cheaper, but it takes more work and more skill. You need to open up the HV battery, disassemble it, remove the old modules, install the new modules, and then reassemble the pack. It should cost less in parts, but it requires more of your time and effort (or paying a technician to do that work), which is the key difference between “modules only” and a fully assembled battery.

I’m not familiar with The Hybrid Geek, but their ad reads well. If they live up to everything they say, then they might be worth a try. Just be aware that these batteries are not new; they use reconditioned OEM modules. That’s consistent with what they say in the listing about the modules being previously used OEM modules that have been reconditioned, tested, and balanced. If you choose this route, you would also be well advised to replace the busbar plates, nuts, and wiring while you’re in there. Those three items can be obtained from ACENBAY and you can save 10% by using the code “SAVE10” at checkout.

Navigating the world of these “reconditioning/remanufacturing” suppliers is pretty hit‑or‑miss. Among the problems is that very few disclose their process. Another factor to consider is the age of the old OEM modules being used. A better option, if you can find it, is getting late‑model NiMH—not lithium—modules from a late‑model wreck. The downside is that it is difficult to find these batteries, as wreckers usually have an agreement with some entity that wants them for their reconditioning business, so the packs get pulled out and go straight to them. That said, they do come up now and again.

The last thing I will say is that I often see people in your position comparing apples to oranges when they compare these reworked secondhand batteries to a new Toyota battery, and you simply cannot do that. These are two very different propositions, and a new Toyota battery has much more value than anything else. In my (very humble) opinion, these secondhand battery offerings should be valued at no more than about 40% of the cost of a new Toyota battery – and that is being generous.

I hope this (not so brief) explanation helps you decode the quoted advertisement and any others you might evaluate in the future.

 

I would add a "block" is two "modules" wired in series. The hybrid system and scanners like Techstream or Dr Prius monitor 14 block voltages, not 28 individual modules.

When you take the battery apart on a Prius you get 28 modules to test. Bad modules are replaced by the "reconditioner" with better used modules. The "better" modules could be 20 years old and can and do fail quickly.

A new oem module easily lasts 10-15 years, sometimes longer. Which means you don't have to worry about it again.

Now that you know what a module is, here is why I would not consider Hybrid Geeks' used mix and match diy modules:

This is a lie. They are not 5% as good as new oem modules. They admit it below.

30 day warranty. Ridiculous. They have no faith in their cheap "reconditioning" of the used modules. You might get a few months of trouble free use after a lot of work that might take two weeks to get going.

Other used battery sellers will give you a year warranty and are likely local to do the work and be able to warranty repair it later.

When your car was bought in New Jersey, Toyota warranted the new battery for ten years and almost all of them lasted 15 years or more.

Here they admit the modules are used. Realize your hv battery is very likely already a used replacement that the car flipper threw in there.

You also have other problems besides the battery! How will you feel after you spend good money and time on a used or new hv battery only to find the overheating engine and bad catalytic converter is still there?

Finally, this video shows what it takes to build a used mix and match battery and stand behind it. If he was close enough to drive to I would say buy from him but only if the other problems are resolved first.

The Hybrid Guy NiMh Battery Rebuild