I have been having hybrid battery problems with my 2012 gen 3 prius for about 6 months. The first code i got were P0B42 hybrid battery voltage sensor (b) circuit low. I serviced the battery by cleaning all corrosion of the battery posts, replacing all copper bus bars with new ones, and new nuts. this still did not fix it, so i replaced battery smart unit/sensor module with one I bought on ebay. the old one had burn marks on two of the pins and on the board. this still did not fix it, so I replaced the entire voltage sensor harness with a new one. the old one had a crack down the plastic connector, a broken wire, and some corrosion. This did fix the P0B42 code, but a new code appeared, P0AFC hybrid battery pack sensor module. The live data on my scanner was showing that most of the blocks were between 15.96v and 16.18v, except for block #8 was at 0v, and the neighbouring blocks #7 and #9 that were both at 24.97. I find this very strange because when i serviced the battery i checked the voltage of every cell, and they were all very close to 8v. I think that would make each block the correct 16v. I decided to use the DrPrius app to see if the battery was charging and check internal resistance. According to DrPrius, the internal resistance is all good. I am not sure what to try next. I also noticed that blocks #7 and #9 appear to be taking voltage from the 0v block. If you add the voltage of the two high blocks (24.97v + 0v + 24.97v = 49.94v) and divide it between all three problem blocks (49.94v รท 3 = 16.64v), you end up with a voltage very close to all the other blocks. I usually would think this is miswiring, but there is only one way to put the bus bars on and you cant really mess it up because they are in plastic channels that only go on one way. If anyone has any idea what my problem is or how to test/fix it, it would be really, really appreciated! thanks!
Most likely, you have a break at one end of the measuring wire that connects to the battery modules. Often, corrosion gnaws through the wire where the round plate is attached. But there may also be a break at the part in the connector that goes into the battery ECU. Corrosion by MAX2 posted Mar 26, 2025 at 3:07 PM