2010 Prius Having issues with HV battery. P3021-23. Modules already replaced

Discussion in 'Gen 3 Prius Care, Maintenance & Troubleshooting' started by GreenTea&SaltWater, Oct 29, 2022.

  1. GreenTea&SaltWater

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    Okay so the story is, I recently replaced all the modules in my battery pack with those of a trusted member of this community. 5k miles later the dreaded "Check Hybrid Battery" error came back up on the dash and the whole screen lit up with lights and decorations more frightening than anything you'll see this Halloween. Initially I thought it was just a bad module or two, but when I replaced Battery block 11, the issue was made worse. This time the "check hybrid" issue would trigger every 1-5 miles whereas before I could drive it 20-30mi before I'd have to pull over and reset the fuse and 12v battery.

    This time when I checked Techstream it now tells me blocks 11-13 are weak. Blocks 11-14 were removed yesterday in order to replace block 11. I'm thinking it could possibly be just that I didn't tighten the nuts enough, so I went back in just now and tightened them better cause they weren't as tight. But I'm wondering if the bus-bars are too corroded? I cleaned them recently 5k miles ago. That doesn't explain why it only says these modules are weak though and not all of them, coincidentally the only ones I removed yesterday.

    Another issue that could be a possibility, is a few repairs ago and maybe 10k miles ago when I replaced some of the modules, I couldn't get them to pack tight enough for the brace to fully lock them in place. The bolts on the bottom wouldn't reach so I compromised with just doing the two top ones. Since I did the very first repair in Dec 2019 about 15-20k miles ago I did not screw the individual modules back to the chasis cause it was far too difficult to do it myself. But I've repaired this pack maybe 7 times since then and this issue where I couldn't squeeze the pack back into place only happened 5k miles ago. I read on here that if you don't wait 72hrs for the pack to cool before removing them they may bulge, I'm wondering if that's what happened.

    What I'm asking if this is a big enough issue to maybe be causing this? Check the pictures and tell me what you think. The bus-bars and vents and sensors all connect perfectly fine. I've also included freeze frame data of when I got the error of when it showed battery block 11 was weak. And also included an image of techstream battery volts with the battery fully strained running high beams, radio, AC, and EV mode.

    The very first time I experienced an issue with my HV it was a P0A80 but recently when I replaced every single module it went away and is only showing this P3021-23.

    Well it seems I can only attach one image here so I will upload an Imgur album:
     

    Attached Files:

  2. Tombukt2

    Tombukt2 Senior Member

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    I had a bunch of this going on when I replaced my engine and transmission in my 13 persona after much fiddle farting around with what I believe was the original HV battery I just got tired of the codes the engine not wanting to start and all this stuff I knew the battery was questionable and had $230,000 plus miles on it The minute I got a battery from hybrid doctor over there in Virginia installed the battery all the problems went away so I guess I'm glad I didn't play around anymore and just swapped it out and was able to see that pretty much was the cure all for that then the battery that I took out I took the covers off and took a good look at and all of the nuts in the bus bars were frosted or starting to look like an old battery positive terminal and a 64 Ford white stuff building up on all of them The bus bars or copper but they were all black corrosion happening I guess The battery from the hybrid doctor has tumbled bus bars balanced within three Delta or something like that they keep saying and ready to go I think I paid $699.was very happy. The battery I took out the hybrid doctor doesn't even want He says it's cooked
     
  3. bisco

    bisco cookie crumbler

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    i think the bus bar cleanliness is pretty important from what i've rad. not screwing the modules to the chassis could be an issue, idk. did you torque everything properly?
     
  4. GreenTea&SaltWater

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    Firstly, woah dude use some punctuation and spacing!! Second, I'd love to be able to just buy a new battery but I can't afford that. The sites I've looked at it's $1500 with a $750 rebate once you send your battery in. I don't have $750 much less $1500 atm.
     
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  5. GreenTea&SaltWater

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    I took a rest drive after torturing the nuts onto the modules properly and so far it's driving fine and feels good. This is only after 15 miles though but before it was triggering anywhere from 0-8 miles so it looks promising. I'll keep the post updated.
     
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  6. Grit

    Grit Senior Member

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    Provide Name please.
     
  7. Tombukt2

    Tombukt2 Senior Member

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    I didn't have it at time either I had to make it . So I drove the other Prii a few weeks . Replaced battery so the persona engine could die. And I could replace that engine n trans .now all running good all three of em .
     
  8. GreenTea&SaltWater

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    OMG I intended to say torquing not torturing this auto correct screwed me! "Torturing the nuts"
     
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  9. GreenTea&SaltWater

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    The battery seems to be working fine for now, 30miles later. Definitely not as bad as it was after I replaced the 11th block. It most likely was that the nuts on the bus bars weren't tightened correctly.
     
  10. Grit

    Grit Senior Member

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    Reread post #6, only 3 words.
     
  11. bisco

    bisco cookie crumbler

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    'new prius lithium batteries'
     
  12. Grit

    Grit Senior Member

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    I give up, who is the person who sold the poster the lithium cells?
     
  13. bisco

    bisco cookie crumbler

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    Either jack or toaster
     
  14. GreenTea&SaltWater

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    Nobody sold me lithium batteries. I don't think I said anywhere that they were lithium?

    This user sold me used modules that he tested himself. So far the replacement has been holding up fine. It was Jim.
     
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