2005 Hybrid Battery Replacement Question Using Dealer Part

Don't add extra stress for yourself.

Just take the big box the new OEM HV Battery comes in, and swap (in/out) the requisite parts. You can take your time to do things correctly. Bring the core HV Battery back the following weekend.

Yeah, it would be nice not to come back, but you are in Phoenix, nearby Camelback (assuming this is the dealer you purchased from).

Hopefully you will be using a torque wrench to properly torque all nuts/bolts.

 

I believe the three system main relays and the current limiting resistor need to be moved as well.

Please identify the dealer that you are buying from and let us know how the experience went. In the event I need to buy a battery for my 2007 in the future (currently have logged 117K miles) I would like to know where in Phoenix to obtain one. (I'm not expecting either of the two Tucson dealers to offer discounted pricing.)

 

You are definitely adding more unnecessary stress to your transaction.

If you plan on turning in your car at the time of picking up you will need to have your pack disassembled and left partially opened, metal cover off. End cap removed.

There are certain things you will want to do to prepare the core before putting in the box. For example putting the 2 brown non-conductive mats over the modules and then installing the metal cover. Also have your VIN and current odometer reading ready to affix to the core, for warranty purposes.

You have an inch-pound torque wrench, right? Post a pic of it here. You want to have it properly set for the terminal and contactor nuts. Only use the 6 new nuts that come with, do not reuse the old ones.

Wrap the connector wires on the core with the bag from the new pack, so that they are protected.

I do these swaps regularly. You'll figure it out eventually.

But give some serious thought about just bringing the new battery home and swapping the parts in an unhurried, low pressure manner.

 

@ericbecky has installed new Toyota batteries. He likely has hints to make the task easier. He has encouraged people to call him with questions. Just look at any of his postings for the phone number.

 

Pay for the core charge, bring everything home and transfer the ecu and relays. After everything is installed, bring back the core

 

Just tell them you are unable to bring the core in at the time of purchase.
Pay the core fee.

You might be able to take the new pack and all the pieces out of their box and leave the box at dealer (it is big). This can save you some space
Alternately the Toyota shipping container can be broken down quite easily if you are short on space. (Like when I used to use a 2-seater Honda Insight for picking up batteries. )
Feel free to call me for other ideas. Happy to help.

And I am going to ask again: Do you have an inch-pound torque wrench?

 

New Toyota packs are missing quite a few things. Not just the computer end of things. It is missing other parts as well; tubes, plastic parts, etc
You don't want to send back your core until you are sure you have all the bits and pieces.

Once you see the new pack and open it up you will have a better idea. But it is easy to miss the small stuff. It's easier to have you core handy so that as you assemble the new pack you can be sure you have everything. Having to run back to the dealer to retrieve something will slow you down.

The torque wrench you have will not work it will snap the bolts even at the lowest setting.

You need one that can do under 50 inch pounds.

 

Sorry. I misread. I thought you only had a wrench that only went down to 120 inch pounds. That would have been too much.
You will be fine with 1/4in drive 20 -200 inch pound wrench.
Service manual will have the specs. Else get a day pass to TIS and print the appropriate procedure/diagram.