Prius 2006, bank 9 failure and ready for repair

After reviewing many posts and videos, I learned how to repair the hybrid battery pack. I ordered two tested and refurbished modules on eBay. The modules on Amazon did not exist or was junk. Surprisingly, could not find a hybrid battery supply house. Dealer wants 3500 Euros that includes 1000 Euros for labor. Not trustworthy. Anyway, the parts arrived, tested both modules at 7.39 vdc. Created a procedure to include bolt and nut size with torque settings. The first phase is the disassembly to the point where the hybrid battery can be moved to the work bench.

 

I inspected the refurbished modules and did not notice any specific part numbers. Also, there was mostly japanese writing on the modules.

 

Good idea

 

Here are the pictures of the purchased modules. The modules were shipped from the UK to Germany. The packaging could have been better than just loose modules.

 

Somehow, the 14mm bolts to the rear seats were super torqued. Required extra muscles. This is to move the rear seats slightly forward to allow access to the hybrid battery bolts.

 

This is what I guessed. Thank goodness for my neighbor and even 30 NM did not work.

 

Well, I new that the modules are used and both measured 7.4v. I with help, disassembled the hybrid battery. Then moved the hybrid battery to the work bench. After disassembly, cover off, I measured the vdc on all modules. All modules measured 8.02 vdc or so. One bank 9 module measured 6.7vdc. I replaced the low vdc module with one of the refurbished modules. After assembly, measured the vdc from module 1 to module 28 +. I saw 0vdc. Discovered that the modules are split. Next is prius start test and final assembly. Anyone ran a test and measured from module 1 - to 28 + ?. For marking, I used 1a, 1b, ...to 14a and 14b. The failed module was 9b.

Also, took bus bars and nuts, placed in vinegar and salt solution. Surprisingly, not as shiny as shown on videos. Maybe something else is missing or requires longer time in the solution. Did not heat the solution.

Is the low voltage module now junk? Seems difficult to tear apart as the module is fully sealed.

 

The problem was solved with a 1/2 inch drive and a muscle guy.

 

I am hoping that the replacement module will get charged by driving the vehicle. I do not know the spec for the 7.2v module but 7.4 is greater than 7.2v. Also, from another video, this is what was done. The next step is a basic test to see if the car will start. Also was initially fooled by checking the battery voltage of 200v. When the safety interlock is removed, then the circuit is not complete. Recording and updating the steps to the procedure.

 

Lesson learned. I should have disconnected the ground terminal from the 12v battery. Car would not start and the 12v battery measured 5v.

 

Ģot a super booster and this helped start the car. Surprisingly, all errors on the dashboard are cleared. For the vent tube, used some Vaseline to help with the installation. After almost everything was completed especially the hybrid battery, we did a test drive to charge up and balance the modules. Will do a final cleanup, update the procedure, and check the apps for final health check, etc.