I need to vent...

It's difficult at first... But over time you refine the sequence of one step after the other. For example the pack is mounted to the rack and four metal rods and two plastic end caps. If you're going to change modules then optimize cooling when reconditioning by taking the rack with modules off the thin metal plate aka, chassis.

When it's time to put the rack w/modules back on the chassis you hang one edge of the pack off the edge of the table and put a mirror under it and use the mirror to see where to bolt all the modules into place. Once you get the mirror in the right position bolting modules down goes very quickly. All 28 bolts under modules and 56 bus bar bolts takes less than 20 minutes once you have an established routine.

And compared to how Honda mounts the NiMH modules, I like Prius way more, it's way less hassle! But perhaps that's just because I've worked on more Prius than Honda hybrids.

 

When the modules are new at the factory they go together in seconds, all used modules have some swelling bulging distortion). They weren't designed or intended to be serviced. Core exchange by a dealer with in house recycling to meet regulations, whatever that is. Thin sheet metal with multiple breaks (engineered bends) to provide longitudinal strength, with reduced weight, weren't designed to be handled by the layman/end user/reconditioner.

 

I agree in some ways. Toyota went a bit overboard in some areas when trying to save weight. That said, how often does the average Prius owner have to replace the HV battery?

From a technical / company perspective, I can understand the "all or nothing" battery replacement rule. Anything else will result in high warranty rates, tie up shop bays for long time, and need special equipment and training for limited return.

Posted via the PriusChat mobile app.

 

They should have been in a slide out tray, and all shipped to a central facility for disposition.

 

A shop loses money if a repaired pack comes back... But if you're DIY and you're doing the work for yourself or your friends, getting back on the road for the cost of a $35 replacement module compared to several thousand dollars is an impressive magic trick. And if that only lasts a little while and you've been honest with the vehicle owner, then you get paid to fix the next bad module. It's a great way to save money a few times. But after a few times most everyone is ready for a new pack.

 

Toyota does replace all modules with new ones as the default solution

This is the smart move

 

Did you try taking it below 6 volts ?

 

Sorry, but it does not work that way. A module with a reversed cell is junk and there is nothing you can do to revive it. Save yourself the hassle and time-wasting and just replace it.

 

And... do not take the modules below 6 volts, or they an be damaged, per panasonic, and industry

 

For the 1400 we spent probably the best deal for this car and just eliminates that for a long long time like the original did my original came out at 19 years and some change and it was failing and the new one has completely eliminated me even worrying about the hybrid battery portion of the vehicle completely don't even look at the bars anymore doesn't matter it's a brand new battery it's working fine.

 

you cant fix a reversed cell, unless u r panasonic

i wouldnt buy a module off ebay unless he gave at least a 10 day warranty and he paid the return shipping if it didnt meet whatever minimum amp hour he says it has, i bet he doesnt say how many ah it has either.

 

I have extra 2 modules that are good if you're interested. I'm supposed to use it but found out that my existing ones are okay, I bought 4 but only used 2.

I bought 2 modules from 2ndlifebattery.com and 2 from a guy in Chicago via marketplace. eBay or Amazon is not my goto place for used/reconditioned modules.

 

Clearly, the module did not have a reversed cell, you need to consider some other explanation for what you observed.

 

You cant undo the damage of a reversed cell, even if it APPEARS to go positive under a hail mary charge, it is ruined. But, it is easy to prevent, do not discharge below 6 volts (1 volt per cell)


Google not only has sheets, they also have powerpoint lol, I MADE THAT

THE ONLY WAY TO PREVENT THIS AND GET ALL YOU CAN GET IS TO DRILL ACCESS HOLES IN THE MODULE AND ATTACK EACH CELL INDIVIDUALLY WHEN YOU RECONDITION THEM, WHICH IS TOTALLY POSSIBLE I HAVE DONE IT ON PRIUS AND HONDA CELLS. WITH THAT METHOD YOU CANT REVERSE A CELL AND YOU WILL GET BETTER RESULTS THAN ANY OTHER METHOD THAT CHARGES DISCHARGES AT THE MODULE LEVEL. IT IS A FACT.

On the honda its easy, the outside metal case is the negative, just insert a probe into the mylar.