P0AA6..and much progress so far.

Received the new thermistor today, and forgot when I originally took apart the battery, there were 2 extra clips laying in the bottom with no sensor ever installed inside. I drilled out one (that plastic is a bear to drill!) and slid the new thermistor inside the hole, luckily the bit I use was a touch smaller than the thermistor, so I carefully wiggled it back and forth until it went in.



Soldered the wires together. Looks sloppy, but the thermistor wires are not copper, not sure what they are.

Also heat shrank them and put the clip back on.



Get everything installed and get P0AA6 which indicates "high voltage ground isolation fault".

There's a rubber body plug where two HV wires enter the body and then continue underneath the car. If I wiggle on a wire, I hear a relay clicking in the HV battery area.

So it seems like there is a short somewhere..somehow. I need to pull the subcode to read into it further.

Here is Dr Prius at the time. Everything else looks good now.

As you can also see..the new thermistor seems to work like a charm.


The white and orange wires were originally reversed...which may of been causing issues before. Turns out the reference photo I used was wrong..

 

At Toyota now. Went through the high voltage area and found no observable issues. My guess is they will need to use a megger to find the insulation leak.

 

Found the issue at home. Toyota upped their labor rate to...$160/hr!
Asked if that came with or without the hooker, they didn't find it funny.
Almost $200/hr is insane.
One of the eBay modules was leaking fluid.

 

This pisses me off so $#@$@# much. This is the 5th time I've had this apart, and one I fix an issue, another one appears!
This is the leaky module.


You can see the electrolyte leaked through and took the paint off.

 

Went a little mad scientist tonight, because I am fed up with having to constantly take the battery apart.

This is one of the modules that was part of the short, I observed no leaking around the terminal, terminal was tight, and after 2 weeks, still held voltage.

Cleaned the end off with some steel wool and put it in the pack. Used my meter to check for any voltage between module and ground before putting bus bars back on, was fine.

Put it all back together and back into the car. Ran the life expectancy test and got 96%!



Drove it 2 hours without issue.