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2005 Toyota Prius-Rebuilding hybrid battery having issues

Discussion in 'Gen 2 Prius Care, Maintenance and Troubleshooting' started by Javamon31, Mar 27, 2017.

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  1. Javamon31

    Javamon31 New Member

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    I bought a used 2005 Prius about 2 years ago. Always wanted one. Last summer the hybrid battery went out. Got the red triangle, lost power, whole nine yards. So I bought a multimeter, took apart the inside, and identified the cells causing the issue. They ranged in V from 5-6.5. I averaged the voltage for all good cells and bought cells on Ebay that were close to that average voltage (7.5). Replaced the bad cells and re-installed the traction battery. Sparks flew. The red triangle light up and another cell had gone bad. Found which it was and replaced it with a new cell. Re-installed only to have sparks fly again and the red triangle light up. As of yet, have not replaced the new cell. Has anyone had similar issues? Is there something else the matter? The V on new cells was very close to the average for the whole system. Not sure what to do.
     
    #1 Javamon31, Mar 27, 2017
  2. JC91006

    JC91006 Senior Member

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    There should be no sparks when you are rebuilding that battery. Where are the sparks coming from?
     
    #2 JC91006, Mar 27, 2017
  3. WilDavis

    WilDavis Senior Member

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    My question would be "sparks? What sparks?" Any sparks would be molto serioso (IMNSHO) - but you've come to the best place for information and help (much needed, by the looks of it!)

    Edit: BTW, Welcome to PriusChat, and you might find a search for "Prolong Grid Balance Charging" to be useful...
     
    #3 WilDavis, Mar 27, 2017
    Last edited by a moderator: Mar 27, 2017
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  4. Sam Spade

    Sam Spade Senior Member

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    The prudent thing to do would have been to replace ALL the cells with new ones.
    And that is STILL the prudent thing to do.

    Actually at this point, I think you need a qualified shop finish the job.......just incase the sparks indicate that you fired something ELSE besides just battery cells. That means having them install a completely rebuilt battery and write off what you spent already to experience.
     
    #4 Sam Spade, Mar 27, 2017
  5. Javamon31

    Javamon31 New Member

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    The sparks come from certain cells when I've replaced the traction battery after replacing bad cells and try starting the car. It hasn't been the replaced cells so far. Those that spark end up being bad too. Beforehand, these sparked cells had registered within a good voltage range.

    Thanks for your response. Not willing to pay the mechanic's fee.
     
    #5 Javamon31, Mar 27, 2017
    Last edited by a moderator: Mar 27, 2017
  6. JC91006

    JC91006 Senior Member

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    If there are sparks, there could be a fire. If you're not willing to pay a mechanic fee and you don't know how to sort this out yourself, then you are just asking for trouble.
     
    #6 JC91006, Mar 27, 2017
  7. Javamon31

    Javamon31 New Member

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    Thanks for your response. The sparks are never significant and never constant. They stop after a single arc. I'm quite comfortable working with these voltages and the sparks. To be clear, I'm not asking for advice on whether to go to a mechanic or not. Thanks again for your input.
     
    #7 Javamon31, Mar 27, 2017
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  8. JC91006

    JC91006 Senior Member

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    sparks flew = single arc?

    Make sure you tighten the connections to 47in pounds. If you have loose connections, you could possibly get sparks (I think)
     
    #8 JC91006, Mar 27, 2017
  9. Javamon31

    Javamon31 New Member

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    Would loose nuts cause the cell to short out?
     
    #9 Javamon31, Mar 27, 2017
  10. JC91006

    JC91006 Senior Member

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    Loose nuts will cause unstable voltage readings and will heat up the modules. This can cause them to heat up and explode/leak. You would need to do a complete rebuild of the battery pack, what you are doing with a multi meter and ebay is just buying you a little time.

    At a minimum, you would need to do the following::

    1. Load test all the modules to make sure they are good, OCV with a multi meter doesn't tell you anything.
    2. Charge/Discharge and balance all the modules
    3. Clean the corrosion of all the copper bus bars
    4. Tighten and clean all connections.
     
    #10 JC91006, Mar 27, 2017
  11. ericbecky

    ericbecky Hybrid Battery Hero

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    Additionally check the cell orientations.
    Any chance they got mixed up?
    Make sure you have it alternating positive, negative, positive, negative,....

    There should never be any sparks.

    Buy a torque wrench and properly torque the fasteners.
     
    #11 ericbecky, Mar 28, 2017
  12. andrewclaus

    andrewclaus Active Member

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    I also suggest proceeding very carefully. You not only have a shock hazard, there are flash hazards and chemical hazards as well. There is considerable chemical energy in the battery. Don proper PPE for these hazards, considering eyes and exposed skin, and flammability of clothing. Cotton is your friend here.

    You have a few very experienced people issuing warnings here. Sparking should never happen, certainly not repeatedly, and it does sound like a very bad sign.
     
    #12 andrewclaus, Mar 28, 2017
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  13. bisco

    bisco cookie crumbler

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    welcome!
    this is the first i recall of anyone having sparks. please be careful, these batteries can be deadly!
    all the best.(y)
     
    #13 bisco, Mar 28, 2017
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  14. Javamon31

    Javamon31 New Member

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    Thanks for the response. Now mixing up module charges is something I would do. Fortunately I had the wherewithal to take pictures beforehand. Definitely not a positioning thing.

    Sparks occur right before a new module fails. It's a minor arcing that is only observable by someone standing around back watching the traction battery while the Prius is engaged.

    Checked the nuts. It's not a connection thing. Read off the codes. P0A94 and P0AA4. Reset the system. Not getting the red triangle but am getting all the check brake lights and the transmission.
     
    #14 Javamon31, Mar 28, 2017
  15. ericbecky

    ericbecky Hybrid Battery Hero

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    Is the hybrid battery secured to the car with at least one mounting bolt that is tightened down all the way?
     
    #15 ericbecky, Mar 28, 2017
  16. Javamon31

    Javamon31 New Member

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    Currently no. It cant be that simple though can it?
     
    #16 Javamon31, Mar 28, 2017
  17. Sam Spade

    Sam Spade Senior Member

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    NO. And just asking that question is further indication that you should NOT be doing this yourself.

    So.....it appears that your only options at this point are:
    Continue to replace the bad cells one at a time.......and keep doing that for months on end until they all are replaced........OR one of them shorts out once it is back in the car and causes a fire.
    OR
    Replace ALL of the cells that you haven't done already and be done with it.

    In the end, either of those options probably won't be that much more expensive than buying a completely rebuilt battery assembly that actually has some warranty.
     
    #17 Sam Spade, Mar 28, 2017
  18. ericbecky

    ericbecky Hybrid Battery Hero

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    The battery pack MUST BE FIRMLY BOLTED IN PLACE. ALWAYS!

    I have seen plenty of problems pop up when the battery is not securely grounded.

    Bolt it down and report back here.
     
    #18 ericbecky, Mar 28, 2017
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  19. TMR-JWAP

    TMR-JWAP Senior Member

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    I apologize ahead of time if I sound rude. There are no circumstances that I can think of that a correctly assembled and installed HV battery would be arcing. An arc occurs and then another failed module? Can you post photos of the battery with the case cover removed? Terminal shields removed? Don't 't forget to remove safety disconnect first.
     
    #19 TMR-JWAP, Apr 4, 2017
  20. TMR-JWAP

    TMR-JWAP Senior Member

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    #20 TMR-JWAP, Apr 4, 2017
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