P0A80, P3022 Repair

After getting codes about the hybrid battery needing to be replaced and never being able to see how the health of the battery is on the HUD, because the spiral cable in the clock spring was no good causing the "oil maintenance required" light to be on all the time and unable to reset it because trip button didn't work.

Having your hybrid battery fail on you anytime is bad but during this pandemic is worse.
I don't have the money to buy a new or refurbished battery and didn't want to give 300-600 to someone on Offerup or Craigslist.

So I took things apart and looked around and found a major issue that was the reason for my battery failing.
I am no mechanic but have always worked on my cars to save money and have experience in electronics.

The battery is a Dorman put in May of 2018 but I had the same issue in February 2019 and they "fixed" it.
Here I am today posting my fix with pictures and my findings.

I do not work for Sears, Green Bean Battery or any other company.
I did however own and operate a car audio shop and know my way around a lot of cars.

The orange plug that is not completely plugged in is the power cable for the side that faces the rear seats.
Take notice of the dot in the center of the plugs and how the one on the right is hidden below the black area.

Once I saw this I was in shock but happy because I may have a shot a saving this hybrid battery.
I pushed down on it and it clicked and looked like the one on the right now.

 

Looking at the bus bars I was happy to see that they were upgraded to nickel plated ones.
There was no corrosion or very little in very few spots, cleaned them anyway.

 

This is the top image of the pack before I went looking for the dirty "mole".

 

Testing each modules voltages to find the "mole"
On the first day I removed the orange safety fuse plug and removed all the bus bars.
Tested each module and ordered one on Ebay for $25
The module arrived on 6/10/20 @ 7.90 volts
By the time I took the battery apart and replaced the bad module with the donor the final voltages were nearly the same.
I don't have overpriced fancy special tools stacked on top of each other to test and load and balance, just a simple multimeter.
The time between days is around 24 hours apart, except on the last day of completion.
Before all this, once I fixed my previous issue with the display not showing I saw where the battery sat.
The battery was only 1-2 bars max once the car was shut off and turned back on, driving it shows it getting full.
That is only the charge going through it while driving though, that actual battery is not charging correctly.

6/7/20 6/8/20 6/9/20 6/10/20 6/10/20 COMPLETE
1 8.03 7.96 7.91 7.87 7.86
2 8.02 7.94 7.88 7.84 7.83
3 8.04 7.98 7.93 7.89 7.88
4 8.03 7.96 7.91 7.87 7.86
5 8.04 7.98 7.93 7.89 7.88
6 8.02 7.96 7.92 7.88 7.87
7 8.03 7.97 7.92 7.88 7.88
8 8.02 7.95 7.91 7.87 7.86
9 8.03 7.97 7.92 7.89 7.88
10 8.02 7.96 7.91 7.87 7.86
11 8.02 7.96 7.92 7.88 7.87
12 8.01 7.95 7.90 7.86 7.85
13 8.01 7.95 7.90 7.86 7.86
14 8.01 7.96 7.92 7.88 7.87
15 8.02 7.96 7.91 7.87 7.86
16 8.03 7.96 7.92 7.88 7.87
17 8.02 7.95 7.90 7.86 7.85
18 8.02 7.95 7.90 7.86 7.85
19 8.01 7.94 7.89 7.85 7.84
20 8.00 7.93 7.89 7.81 7.80
21 8.02 7.96 7.91 7.86 7.86
22 8.03 7.96 7.92 7.88 7.87
23 8.04 7.97 7.93 7.89 7.88
24 6.67 * 6.59 * 6.53 * 6.47 * 7.88
25 8.03 7.96 7.91 7.87 7.86
26 8.03 7.96 7.92 7.88 7.87
27 8.04 7.97 7.92 7.88 7.88
28 8.03 7.97 7.92 7.88 7.87


After the installation of the battery, even after shutting the car down the battery holds its power and shows 1-2 bars away from being full.

 

Display, whatever you want to call it, you know where you see the hybrid battery information correct?

 

Low mileage module from Ebay only cost $25

Posted via the PriusChat mobile app.

 

This is my pack with Block 12 # 24 module replaced.

Posted via the PriusChat mobile app.

 

Now it is a happy battery holding charge under A/C load in Eco mode

Posted via the PriusChat mobile app.

 

Ok I got you buddy, I called it the wrong name, but you do know where every prius shows its battery activity and information correct?

Posted via the PriusChat mobile app.

 

I know that and have not uploaded my screenshots yet. You have still not confirmed that you know where the battery indicator is on the dash. Instead you are correcting me for using the wrong term for the display and assuming I didnt use an OBD2 scanner.

Posted via the PriusChat mobile app.

 

You can see where the the rest of the pack was starting to degrade showing a code for another block.

Posted via the PriusChat mobile app.

 

Screen shot of battery pack on 6/7/20 with the ICE off just pressing twice on the start button.

Posted via the PriusChat mobile app.

 

This is today without the ICE being on just pressing the start twice and sitting overnight. I think block may be next but we will see if more driving can fix that, I have only driven it for a few days since the fix.
Outside temp is 88F at the time
The car is black but has limo tint.


Posted via the PriusChat mobile app.