P0A80 advice...

Discussion in 'Gen 3 Prius Technical Discussion' started by Paul E. Highway, Oct 5, 2021.

  1. Paul E. Highway

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    Aloha!

    I've read just about every P0A80 thread on here and now have my own!

    Got the dreaded P0A80 code while driving with 168,067 miles. Car is 2010 but traction battery was replaced under warranty for original owner in 2015 with 62,616 miles, so battery is 6 years old and has about 105K miles on it.

    I thought because of battery age it was a good candidate for Prolong, so got the charger/discharger package and did the charge/discharge per their instructions. Cleared code (still had permanent code, though) and drove for about 300 miles when code on dash returned. Car was running great battery-wise after the charge/discharge.

    Dr. Prius app says battery is at 38.66% capacity, and has a weak block at #8. Decided to load test the modules yesterday. Car sat for 2 days before I ran the 2 minute load test on each module. The bus bars had some corrosion on the exposed parts but I already have new nickel plated bars ready to install when I put things back together.

    This car was doing 800 miles a week before COVID as an UBER, does not use oil and coolant level is stable, would be nice to keep it going for a while. It's a very early Gen 3, VIN ends in 0001293! Has had a fairly easy easy life in Hawaii, where the temps are 70-90F almost every day.

    My next step will be replacing the bus bars, doing another charge/balance, and then another load test. I have no problem replacing a couple modules if needed (they look pretty consistent, though) but if it's more than that will probably order a new pack from newpriusbattteries.com

    Any comments on the module test numbers appreciated!

    PEH





    Dr Prius report.jpg bus bars.jpg
     

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  2. bisco

    bisco cookie crumbler

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    i don't have anything useful to offer, but i'm shocked that such a young, low mile battery is testing so poorly.
    i have to wonder if it was one of those experimental toyota replacements that they gave up on.
     
  3. Paul E. Highway

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    another piece of the puzzle could be only driving 30 minutes or so per week during the pandemic, was not doing any Uber driving from March 2020-February 2022.
     
  4. ASRDogman

    ASRDogman Senior Member

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    You should drive it more. Maybe an hour at a time? Give the battery time to work maybe?
     
  5. Paul E. Highway

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    When the code appeared I was back on the Uber grind for a month or two, was probably driving about a hundred miles a day. Wondered if the long layoff affected my battery.
     
  6. TMR-JWAP

    TMR-JWAP Senior Member

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    Please do me a small favor and let me know what the winning powerball numbers were for one of the drawings in December 2021, so I can give my wife an awesome Christmas present!!
     
  7. mr_guy_mann

    mr_guy_mann Senior Member

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    What does Dr Prius show for voltage differential? Which block number (in the data- not the battery "life expectancy" test) has the lowest voltage? Unless the voltage data points to a fault with the battery ecu / connector for the voltage sense wires, then you should start by seeing which block(s) have a failed module.
    Grid charging after you have a code is like exercising after you feel the pain of a heart attack. Ain't gonna help because it's too late.

    Posted via the PriusChat mobile app.
     
  8. Paul E. Highway

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    Good points.

    Dr. Prius pointed at block 8, which load tested like this on Monday:

    before test after test voltage loss
    15 7.85 7.40 .45
    16 7.84 7.37 .47

    Here's 2 screen shots from Dr Prius app, one shows block 8 at the bottom, the other shows block 8 at the top. 5 days apart.

    I will say, the app show block 8 at the bottom more than any other block.

    I've seen voltage differential as high as .42 here and there.
     

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  9. bisco

    bisco cookie crumbler

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    sitting is definitely bad for older nimh batteries. there's a slow chemical change, and then they go

    BOING!
     
  10. Hi_prius3

    Hi_prius3 Junior Member

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  11. Hi_prius3

    Hi_prius3 Junior Member

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    Howzit Paul. I’m in Honolulu and my 2010 Prius just got the P0A80 code. It has about 117k miles. The car wasn’t being driven much for about a year because of COVID-19. Servco wants to replace the hybrid battery for $$$$. I have 3 bad blocks/modules according to the Toyota scan.

    I’d like to know how you plan to repair your hybrid battery since I need to do the same. I was thinking of replacing the bad blocks/modules, then doing the Prolong reconditioning also. Lmk how your progress goes, or how we can get a new reconditioned hybrid on island for a reasonable price. Mahalo
     
  12. ASRDogman

    ASRDogman Senior Member

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    Do you have the Prolong system? If so, why not run it through it's cycles, 3 discharges and 4 charges,
    before you start replacing modules?
    It might recondition the apparent bad modules. And it certainly can't hurt to do it.

     
  13. BiomedO1

    BiomedO1 Member

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    When you stated that you "load tested" block 8; did you physically remove the batteries in block 8 and used a carbon pile load resistor to test the two cells separately? This is the only way to definitively test a battery - software diagnostic can only take you so far.
    Go to Harbor Freight and get a carbon pile load tester. Test each battery in block 8 separately with the bus bar off; also check the two blocks adjacent to block 8 - since they had to carry the additional "load". A carbon pile load test is 30 sec. max. per a cell; read the instructions. Don't use one of those digital battery testers; they lie. I've had batteries pass a digital tester; but would fail a carbon pile load test. They still had voltage, but wouldn't start a car.

    Good luck...

    IMHO; regarding the Prolong - if you have a bad cell/battery; no amount of reconditioning is going to bring it back. Your dealing with a decline in the battery's internal wafers and chemistry. You also got more than 100k miles out if it, which is it's estimated useful life. I'm sure most daily drivers get a lot more mileage out of a pack; but again - its' a "daily driver".
     
    #13 BiomedO1, Oct 24, 2021
    Last edited: Oct 24, 2021
  14. ASRDogman

    ASRDogman Senior Member

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    It will NOT hurt to run the Prolong system. I only had 243850 miles on my 2010 Prius when
    I ran the Prolong system. I worked, for me. There is a big difference how the battery charges
    and discharges. And I gained 4mpg! I cleaned the rear bus bars, but they weren't really bad
    at all. The fronts were good, only minor "greening" on the Positive and Negative terminals where
    the harness connects.
    And since changing 1 or 2 cells is just doing the wak a mol thing, why not replace them all?
    I agree is a cell is damaged, there's no fixing it. And if you already have the Prolong system,
    why NOT use it?
    If you don't have it, then do the other test.
     
  15. Paul E. Highway

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    Great comments, thanks.

    I did the load test on each module with bus bars off with H4 headlight bulb timed for 2 minutes. Results were posted in my original post.

    I replaced all the bus bars with nickel plated and went through the Prolong charge/discharge procedure again. Still getting the replace hybrid code every couple hours of driving, I clear with Dr Prius app. But not driving as much until I resolve. Have a spare car.

    May try the carbon pile load test.

    Considering a New Prius Batteries pack…

    PEH
     
  16. BiomedO1

    BiomedO1 Member

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    A H4 bulb draws less than 5 amps. Rig an old fry- or heater- lamp for a good current draw to test your battery. You can just replace all cells that fall below 0.45 volt using your H4 test; but I don't believe that's enough of a load.
    If you ever had a car with a dead battery, the first thing you do is turn on the headlights to see if the battery has power. If your headlights turn on; you try to crank the engine with the headlights on - the battery is dead or you got a loose connection, if the headlights go out while trying to turn over the engine. The same applies here; some of your cells are borderline - that's why it takes a few hours of operation to throw the code again.
    I would focus on 5,16,18,19, and 21. At a min.; I would replace 18, 19, and 21 - that should get you back over 50% on the Dr Prius App.
     
    #16 BiomedO1, Oct 24, 2021
    Last edited: Oct 24, 2021
  17. Hi_prius3

    Hi_prius3 Junior Member

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    I do not have the Prolong system. I will get a HF carbon pile load tester and check the bad blocks. I’m watching this thread and waiting to see how successful Paul is in reviving his hybrid battery. Hopefully he is, then I can do the same.
     
  18. Paul E. Highway

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    FYI I checked Harbor Freight and they only have one carbon pile load tester, it is on closeout and in-store only, so not available to me. Looked around the web, lots of units out there, but they mostly say for 12 volt lead acid batteries. Don’t know enough about them, can they be used on a hybrid NiMH module?

    Hi_Prius3, if you go the Prolong route I might be able to rent you my charger and discharger for a small fee. Lmk.
     
  19. Hi_prius3

    Hi_prius3 Junior Member

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    Hi Paul. I may take you up on the Prolong rental, maybe later next month.
    I will be traveling to the mainland in 2 weeks and plan to pick up the HF carbon load tester then. I can let you use it if you want.
     
  20. Paul E. Highway

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    Ok sounds good
     
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