Is this a normal about of corrosion for bus bars under a year old?

Discussion in 'Gen 2 Prius Technical Discussion' started by Banksy, Jan 5, 2021.

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  1. Banksy

    Banksy Active Member

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    So I had to pull my HV battery today

    Replaced it in February and had two modules fail

    Got replacements from company I bought it off for free

    Noticed a lot of corrosion in the bars

    Is this due to excessive moisture?

    Is this a lot?

    I only say that because this prius does have water that pools up on the driver's side rear near the tail light / small storage bin

    Some input and advice would be greatly appreciated

    Also... due to a bad experience I just had with a local dealership I was offered a new complete pack for 1700 if I provided my current one as a core

    Good deal?
     

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  2. PriusCamper

    PriusCamper Senior Member

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    Yes, that's fairly normal, but less common in dryer regions... As far as I know the only time this turns into a problem is where the orange voltage sensing harness plugs into the battery ECU socket. Once the corrosion gets in there it can short circuit the pins and fry the voltage sensing harness and sometimes fry the ECU as well. The symptoms for this problem is voltage block readings that are changing often and are wildly inaccurate/make no sense.
     
  3. sam spade 2

    sam spade 2 Senior Member

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    You do realize that the "new" battery you got in Feb. really was NOT new.......right ??
    Sounds like your rebuilder did a poor job.
     
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  4. Banksy

    Banksy Active Member

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    I absolutely realize that
     
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  5. Banksy

    Banksy Active Member

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    The bus bars were though
     
  6. Banksy

    Banksy Active Member

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    Don't think I ever used the word "new" in my post

    Now this pack just fell about 5 ft onto the ground do to my bench deciding to give out

    Case doesn't look damaged

    Modules look fine

    Is this thing probably toast?
     
  7. PriusCamper

    PriusCamper Senior Member

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    I've found the most effortless way to clean bus bars is to put them all in a rock tumbler for a day or two...
     
  8. mr_guy_mann

    mr_guy_mann Active Member

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    Can't say for sure. My concern would be the shock at the module mounting screws possibly resulting in a crack. If it was still on the bench top as it fell (ie, the case itself didn't impact the floor) then I would think it was ok.

    The bare copper of the original bus bars corrodes real quick unless coated with something. I just got a set of the nickel plated bars from ebay.

    Posted via the PriusChat mobile app.
     
  9. alftoy

    alftoy Active Member

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    Ooops. Maybe take the dealer up on his $1700 offer.
     
  10. Banksy

    Banksy Active Member

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    I was just looking at the quote

    That's with tax I think because it didn't mention any tax

    Just 1650 and the core
     
  11. ozmatt

    ozmatt Active Member

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    It is absolutely 100% moisture related and will ruin your battery (and rest of car) if you don't get on top of it asap..

    Seal the roof welds under tail gate, seal tail lights ..

    consider removing the little grommets in rear under corner tray and 12v battery so any water can drain if it does enter

    Put $2 shop dehumidifier containers in car and replace as required


    Good luck!
    IMG_20201229_150100_811.jpeg IMG_20201229_102433_235.jpeg

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  12. PriusCamper

    PriusCamper Senior Member

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    Maybe you can eliminate moisture in Australia, but where I live in Pacific Northwest we have the highest year round humidity levels in the country and there's no way you can eliminate it, you just have to live with it and minimize the damage it causes, which isn't that bad for most Prius owners.
     
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  13. ozmatt

    ozmatt Active Member

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    its hard to control nature hey! i want more sun..
    its pretty "soggy" down south here where I am

    For me I just keep the vent on recirculate rather than open, keep car clean and dry, windows up and ac on .. as mentioned seal roof welds and put a few dehumidifiers in the car..

    You can keep it mostly under control if you are careful
     
  14. PriusCamper

    PriusCamper Senior Member

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    Our local Prius gang likes to coat everything in Di-electric grease to prevent corrosion and then when they ask me to work on their pack it's a huge mess and hassle for me and I complain bitterly. Have to wash my hands again and again when I work on those packs. Trying to prove to them that a little corrosion is way easier to deal with than my endless complaining about my hands and tools getting greasy.
     
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  15. ozmatt

    ozmatt Active Member

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    Priuscamper, I'm so glad you mentioned this, have been considering the use of Dielectric but after reading this I definitely won't bother because I have a skin condition and washing hands too much is the best way to irritate them! thank you

    Posted via the PriusChat mobile app.
     
  16. PriusCamper

    PriusCamper Senior Member

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    If you're putting in a brand new pack or reconditioned pack that's never had a bad module it makes sense to limit corrosion. But if your replacing a module your going to have to go in and do more work in 3 months to 3 years, so it's not worth the mess it makes.
     
  17. Banksy

    Banksy Active Member

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    Do you have a link to those canisters you mentioned?

    also where could I get some more of the weather stripping that's on the hatch

    is that a common thing to cause this too?

    also.. di electric grease

    Do you apply it to the front and back of the bus bars?

    Or just slap it all over the front?
     
    #17 Banksy, Jan 10, 2021
    Last edited by a moderator: Jan 11, 2021
  18. ozmatt

    ozmatt Active Member

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    I am in Australia so you may need to do some searching your end of the planet but here is an example of what i use ..


    DampRid 300g Refillable Moisture Absorber | Bunnings Warehouse


    not too sure about the weather stripping mate sorry i will leave that for someone else :) but address the welds at the top of the tailgate where the rear panels meet the roof, i will be sealing one in the next couple days and will try to get photos if i remember

    I decided not to use grease its too messy for me, so not sure how to advise about that either sorry :)
     
  19. PriusCamper

    PriusCamper Senior Member

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    DampRid will get rid of very little moisture. When I have a prius that's get wet inside I put in my 40pint home dehumidifier and inside of car is super dry in less than a few hours.
     
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  20. ozmatt

    ozmatt Active Member

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    No they are not for quickly extracting a real big mess,, its just a nice precautionary in the rear corners of clean dry cars after they have been sealed to collect any residual dampness in the cabin

    swap them out when the container is full which is about every 4 to 6 months for me

    & now that you mention it :) good idea.. I will grab a home unit the same as yours to use when giving cars annual once overs
     
    #20 ozmatt, Jan 12, 2021
    Last edited: Jan 12, 2021
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