HV battery Dead on 2006 Prius HELP!

Discussion in 'Gen 2 Prius Care, Maintenance and Troubleshooting' started by Sherri167, Jun 5, 2012.

  1. Sherri167

    Sherri167 New Member

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    usnavystgc,
    That is what my husband is telling me. He wants to do it himself.
    My fear is that point you made about it may last me 6mos, maybe more, maybe less.
    It will do GREAT I am sure, till I am on my way to final exams or something extremely important school related that I cannot miss. Thanks to Murphy.
    I am very concerned about that.
     
  2. usnavystgc

    usnavystgc Die Hard DIYer and Ebike enthusiast.

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    That's what I would do if in your situation. At this point you don't have anything to lose.
     
  3. Sherri167

    Sherri167 New Member

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    Are you happy with changing out the cells on yours?
     
  4. Sherri167

    Sherri167 New Member

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    I read your links. I guess I'll suck it up and let him try. Make him get enough life insurance to pay off the mortgage before he starts. ;)
     
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  5. jdenenberg

    jdenenberg EE Professor

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    I didn't change out my cells. I installed a ReInVolt for $2000 and after rehabbing the 27 good modules, sold them to 7 other people (some here and some on eBay) so that they could fix their HV batteries. The $700 that I cleared after expenses made my net cost $1300 for my repair.

    JeffD

    ps: I still have the good Battery ECU from my 2004 Prius HV battery if anyone needs one.
     
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  6. usnavystgc

    usnavystgc Die Hard DIYer and Ebike enthusiast.

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    Here's a better question for Jeff:

    If you had to do it all over again, would you just change out one cell and save $1260 and eliminate the hassle of selling the batteries?
     
  7. jdenenberg

    jdenenberg EE Professor

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    I would have to buy a set of modules so that I could find one to match my existing ones in capacity and series resistance. I would also buy 3 more charger/re-balancers so that the job could be done in a reasonable amount of time (about two weeks). This would cost $250 and the unavailability of my Prius for that duration.

    My other option would be to buy a salvaged, low mileage battery for about $1000 and still buy three more charger/re-balancers (about $100). Then I would refurbish/test all of the the salvaged unit modules while my Prius was still drivable (if limping) and after swapping the batteries, sell the remaining good modules (after testing and re-balancing) to bring the overall cost down to about $400 and again get the pleasure of helping several others to get their HV batteries going.

    Of course this assumes that my ReInVolt battery fails before some other costly repair ends the useful life of my 2004 Prius which now has been driven 225,000 miles (30,000 on the ReInVolt).

    JeffD
     
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  8. Sherri167

    Sherri167 New Member

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    Well guys, it's taken hubby a while, but the battery repair is to begin tomorrow. God willing.
     
  9. josh2008

    josh2008 Active Member

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    I have a rebalanced battery for sale if you end up needing it :)
     
  10. Sherri167

    Sherri167 New Member

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    Thanks Josh. Hopefully I wont!!
     
  11. khp

    khp Member

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    Sherri,
    I bought some rebalanced modules from Jeff around October 2011 and replaced 3 modules in my 2006 Prius.and my Prius is working great since I have. I have put on 30k miles since and all is well. The biggest thing you have watch is being careful removing the battery and the high voltages. The other thing is get the voltages as close as possible when replacing the modules. If I remember correctly I think the spec is no difference of more than .200mV between the modules. I discharged my to .020mV within each other. As far doing the whole job if was relatively easy in comparison to other automotive repairs. A lot better than engine or trans work... Best of luck and there are some very knowledgeable members of this forum which helped me out.
     
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  12. Sherri167

    Sherri167 New Member

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    Here is the update.
    Car is worse now than previously. The one positive is no more fan noise. Every light on the dash is lit. Will only go to park or neutral. Shows voltage from the battery but the computer will not switch the silenoids (what my husband says), so the electric engine does not get power. Have absolutely no clue. Not at all happy.
     
  13. Patrick Wong

    Patrick Wong DIY Enthusiast

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    Tell your husband to check the orange traction battery interlock switch located on the traction battery case. I assume he removed it for safety reasons before he started to work on the traction battery.

    When the switch is inserted, the handle must be pivoted 90 degrees. Then the handle must be slid to lock it in place. The second part of that procedure is frequently forgotten.
     
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  14. Sherri167

    Sherri167 New Member

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    He has voltage to the silenoids. If he removes the interlock system he loses that voltage. So we are good there.
     
  15. Sherri167

    Sherri167 New Member

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    Is there a way to re-initialize the ECU?
     
  16. Patrick Wong

    Patrick Wong DIY Enthusiast

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    Disconnect the 12V battery negative cable where it bolts to the body for a few minutes. That will allow the ECUs to power down.

    He also should measure the voltage of each of the 28 modules. If any one module's voltage differs by more than a few tenths of a volt compared to the others, the battery is not going to work.
     
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  17. Sherri167

    Sherri167 New Member

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    CORRECTION:
    Nope, the interlock was not slid down Patrick, I double checked. Put the key in, nothing. NOTHING.
    He had been talking and me not listening, the whole car had shut down while I was in the house.
    We just looked at each other and thought YELLOW TOP. Checked it and it is low. So we are doing a slow charge on it right now.
    Maybe things will look brighter in the morning.
     
  18. usnavystgc

    usnavystgc Die Hard DIYer and Ebike enthusiast.

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    Hey Sherri,
    Stick with it. You guys will get it. Be patient and don't give up.
     
  19. Sherri167

    Sherri167 New Member

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    Sorry, I had class today 8-4 and just got home.
    THE CAR IS RUNNING. No dashboard lights, no codes, driving like it used to! Hubby drove it to work today. He still wont let me drive it, doesn't trust it yet (I tried to trade with him when I got out of class). But it is looking VERY GOOD!!! I am now, a very happy camper!!
    The yellow top last night was only at 4volts, and that was causing our problem. Along with the issue Patrick brought up regarding the interlock.
     
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  20. Patrick Wong

    Patrick Wong DIY Enthusiast

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    I'm glad to hear that you can declare victory on this.

    I am wondering what caused the 12V battery to discharge to such a great extent that it only measured 4V?
     
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