Prius Battery Replacement Kit (GenII/GenIII) with NEW custom cells

Discussion in 'Gen 2 Prius Main Forum' started by 2k1Toaster, Oct 13, 2017.

  1. 2k1Toaster

    2k1Toaster Brand New Prius Batteries

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    What is this?
    This is a DIY kit to completely and fully replace your aging or dead Toyota Prius Hybrid Battery (a.k.a. Traction Battery) with brand new battery modules, bus-bars, battery wiring harness, and interconnects. You retain your original metal enclosure and hybrid ECU.

    Will this work with my Vehicle?
    This is meant for Generation-2 Toyota Prius vehicles, model years 2004 through 2009. We also have kits available for Generation-1 (2001-2003) and Generation-3 (2010-2015) available with request. These modules will work in any number of Toyota and other makes that use the same Panasonic battery design, but the wiring kit is specific to the Prius. With extra (and non-supported) DIY, you could potentially make it work with many more vehicles.

    Brand New Batteries
    Not a refurb or rebuild. These are brand new modules fresh out of the factory and have never been in a vehicle. ZERO miles driven.

    Superior Design
    Cylindrical cells, half the battery modules, and all the same functionality. Upgrade your Hybrid Pack today!

    Factory Warranty
    A 2 year or 25,000 mile warranty on the modules. Fleet vehicles included.​

    How Much?
    For $1600 and approximately 4 hours of installation time, you will get a brand new hybrid battery backed by a 2-year or 25,000 mile warranty including fleet vehicles. There is nothing comparable out there. All other options that are not original Toyota Hybrid packs, are used modules. Some are refurbished and/or balanced to be better matched with one another, but they are still all used batteries from wrecked, salvaged, totaled, or other failed Prius vehicles. In contrast these batteries from NewPriusBatteries.com are brand new and never used. When you start driving on your new pack, it starts with zero miles on it, just like a brand new Prius from the factory.

    The Smarter Financial Investment
    Don't waste your money on refurbished or re-manufactured batteries. The only real solution to repair your Toyota Prius Hybrid Battery is to replace the entire pack. Anything else is a temporary band-aid, akin to playing the game whack-a-mole. Why spend the same money to put in used modules inside a refurbished pack instead of buying new modules?

    Doing the Math
    This battery is the smartest choice for any Toyota Prius needing a Hybrid Battery pack replacement.

    Prices listed below are what you will pay at the counter. In all cases except for our battery, you will be charged a core exchange fee, that you get back after they receive your old battery back in acceptable condition. Toyota dealerships are hesitant to sell the average consumer a hybrid battery over the parts counter, and most will refuse you service unless you get them to do the installation as well. All prices below are for the Toyota Prius Hybrid Battery Pack itself, no installation included. Most (All?) dealers will not install a re-manufactured or refurbished battery. Most independent shops will only install full units. Ours is a kit, and requires opening the battery to replace/swap components. Any hybrid battery rebuilder service in your area should be able to do this work. Prices vary greatly throughout the country and again depends on if you want it to be done in a shop or in your driveway. This is something you can do if you are careful around high voltage and handy with a wrench.

    • Dorman Battery (Remanufactured)
      • $2400 - These packs are assembled and tested by Dorman by using a large inventory of used modules. Careful pairing of used modules attempts to create a balanced pack, but the modules may be of any age with any amount of mileage on them. A used battery in a pretty case.
      • $950 core charge included in price.
      • $1450 total cost after core refund for a used pack
    • Best Toyota Price (NEW)
      • $3450 - This is a brand new Toyota battery, using genuine original parts ordered from a dealer without installation. If they will actually sell it to you over the counter, there are only a handful of dealers in the country that are willing to honour this price.
      • $1350 core charge included in price
      • $2100 total cost after core refund for a brand new pack from Toyota
    • Normal Toyota Price (NEW)
      • $3939 - This is a brand new Toyota battery, using genuine original parts ordered from a dealer without installation. If they will actually sell it to you over the counter, this is the average price you will be charged.
      • $1350 core charge included in price
      • $2589 total cost after core refund for a brand new pack from Toyota
    • New Prius Batteries.com (NEW)
      • $1600 - This is our brand new aftermarket battery, using brand new modules without installation. Individually serialized, lab tested, performance crafted.
      • $0 core charge. There is NO core charge, you keep your original Toyota battery.
      • $1600 total cost. That's it. Did we mention free shipping? No? Well free shipping within the continental USA.
    As you can see the standard Toyota battery is just under $2600 for the pack. This does not include installation costs and remember a new pack from Toyota still requires swapping some hardware from your old pack to your new pack, it is not a drop-in-replacement with zero effort. It takes the same effort to replace the HV pack for all of these and both Toyota and my solution require you opening the HV case and doing a little bit of work in there. The $2100 price is awesome for a new Toyota pack, but it is like a unicorn. Recently, I haven't seen anyone get that price outside of the local area of 2 or 3 places across the US. They will ship, but for a few hundred dollars. In contrast, this kit is $1600 with free shipping anywhere in the lower-48.

    Standard Installation Flow
    These kits are no more difficult to install than a standard battery swap. In fact, it is recommended to follow one of the many YouTube videos of how to disassemble your Prius to access the Hybrid Battery and to put it back together.
    • Disassemble Prius to Access Hybrid Battery
      • This involves removing the false floor, some interior plastic panels, and disconnecting the rear seats. All can be done with a socket wrench and a screw-driver. A power-drill is recommended with a socket attachment to make life easier. Average time for a first-time disassemble is roughly 1 hour. An experienced rebuilder can usually do this within 5-10 minutes.
    • Remove Hybrid Battery from Vehicle
      • This is a heavy part, it is best to have help. You will need to access the bottom of the pack, so it does need to be fully removed. It cannot be worked on in the car.
    • Disassemble Original Hybrid Battery
      • Remove the cover, remove the battery nuts, remove the bus bars, disconnect the venting, disconnect the temperature sensors, remove the tension bar, and end up with the shell of a battery. Since there is no core charge, you are welcome to keep your old modules or to sell them on eBay for others venturing to make refurbished used packs to help offset the cost of your brand new pack! Remember if you ever intend to extract a core exchange fee, you will need your original modules at this time.
    • Assemble NewPriusBatteries.com Brand New Hybrid Traction Pack
      • Line up your modules in serial order. Each of the 14 modules is marked from #1 through #14, and put them in order. Attach the bus-bars, battery nuts, and new wiring harness. Move battery to original enclosure. Attach temperature sensors via included clips. Attach modules from the bottom to the original battery enclosure. Complete the wiring, and put the cover back on the battery. That's it! Average time for a first install is about 1 hour if you are taking your time.
    • Re-Install Hybrid Battery in Vehicle
      • Again, this is a heavy part and it is best to have help. Carefully place the newly assembled battery back into the Prius.
    • Reassemble the Prius
      • Now it is time to put all the bolts, screws, and plastic panels that make up the rear of Prius back together. This may take an hour for a first time builder, again 5-10 minutes for an experienced installer.
    • Complete Install
      • Make sure to latch the orange safety interconnect back in-place (it can be tricky!) and READY the vehicle. If you have codes, it is best to clear them before driving. Your brand new battery is now installed and should be trouble free and worry free for a very long time. You also have the peace of mind that your brand new battery from NewPriusBatteries.com is fully warranted for 2 years or 25,000 miles, whichever comes first. In the unlikely event of a warranty replacement, we will send you a new battery module for you to install.
    Included in the Kit
    The NewPriusBatteries.com Prius Battery Kit requires some installation. If you are not comfortable working with high voltage DC, any hybrid battery installer local to your area should be able to provide the service for you, and the installer may contact us with any questions.

    • 14 Cylindrical Battery Modules
      • The life-blood of your Hybrid Battery Pack
    • Bus-Bars and Nuts
      • Solid metal bus-bars and nuts to connect the battery modules together and to the enclosure.
    • Wiring Harness
      • A new wiring harness to connect to each of the 14 modules, the safety interconnect, and the HV ECU.
    • Mounting Screws
      • To secure the battery modules to the original Toyota metal enclosure.
    • Battery Module Spacers and Covers
      • Orange and Black High Voltage plastic spacers to secure the battery modules and limit exposed high voltage connections.
    • Temperature Sensor Mounts
      • Three plastic clips that secure the original temperature sensors to the new battery modules
    Pics or it Didn't Happen

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  2. 2k1Toaster

    2k1Toaster Brand New Prius Batteries

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    Reserved #1
     
  3. 2k1Toaster

    2k1Toaster Brand New Prius Batteries

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  4. 2k1Toaster

    2k1Toaster Brand New Prius Batteries

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    First shipments have gone out!
     
  5. ericbecky

    ericbecky Hybrid Battery Hero

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    I've purchased my kit and received it a few days ago.
    Well packaged and labeled.

    Even though it takes relatively little time to assemble (4hrs?) I'm guessing that someone else will beat me to being the first assembled and installed unit. (Dang.)

    All my (3) Priuses have functioning packs, so this wasn't really something I personally needed. But I wanted to try it first hand before installing in customer cars.

    I'll report in as things progress.
     
  6. ericbecky

    ericbecky Hybrid Battery Hero

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    OK. Took a moment to open the rest of the boxes that were inside the big box.
    Here are some pics of the pieces. (with my business card in the photo. I put that there. It did not come with the kit. Lol.)

    PriusChat is having trouble adding photos right now. So here is a link to an album in Google photos.
    https://photos.app.goo.gl/bDJiFOJzwPhEClCs1
     
    gptx, kenoarto, Shane Burns and 3 others like this.
  7. 2k1Toaster

    2k1Toaster Brand New Prius Batteries

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    Thankyou for sharing the images. The site appears to be approaching normal again...
     
  8. wjtracy

    wjtracy Senior Member

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    Side question- out of curiosity what are you planning to do with Reserved #1 and #2? As we quickly lose edit access, but I guess Tideland might help you out.
     
  9. 2k1Toaster

    2k1Toaster Brand New Prius Batteries

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    With XenForo it is really hard to put posts out of order chronologically and there is a max size limit per post. So eventually with more info, more images, more text or just more detail I might run out of "post-0 space" and then it would have to go pages down the thread. With a reserved, the post is made and the content changed later. I won't be able to change it without a mod's help, but it is then possible.
     
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  10. 05PreeUs

    05PreeUs Senior Member

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    If my replacement #6 module does not completely fix her, I'll be next :)
     
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  11. FireFighterHill

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    Timeline for the release of a GEN 1 kit?
     
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  12. tamerlano

    tamerlano New Member

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    I would like to ask a few questions that have not been answered on your website::?
    Is your battery pack lighter or heavier than the OEM one?
    Would it be possible to have a battery with more capacity than the OEM?
    From the photos I see that there is space between the elements. Does this space help to dispose of the heat produced by the battery pack using the OEM fan?
    Thank you

    Inviato dal mio VIE-L09 utilizzando Tapatalk
     
  13. ericbecky

    ericbecky Hybrid Battery Hero

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    I should mention that the photos I've put in the album are without reading any specific instructions. So at this point I may have things installed improperly and will have to go back and correct.
    I'm putting it together in short segments while doing other unrelated things.
    You should pay a bit more attention to things when you get your kit. Do as I say, not as I do.
     
    Robert Holt, kenoarto and 2k1Toaster like this.
  14. 2k1Toaster

    2k1Toaster Brand New Prius Batteries

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    A Gen1 kit does technically exist, it is just a different wiring harness and more cells. But I don't have a Gen-1 to test on. If a time comes when you need a pack and want one of these for a Gen-1, we can make arrangements.
     
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  15. 2k1Toaster

    2k1Toaster Brand New Prius Batteries

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    Basically the same. Half the modules of double the capacity, they come out roughly equal.

    Not with this kit.

    There is no reason for more capacity. Back in the day, lots of us experimented with extra packs or even full conversion kits. The Prius doesn't really care if you have tons of extra battery, it is a gas powered vehicle at the end of the day. Unless you add a plug, you're going to get roughly the same mpg. Back then, it made sense to do a PHEV conversion on a Prius and run it in OOG mode (Out Of Gas mode for pure EV) but now you can pick up a used Nissan Leaf that does all of that from the factory for less than a conversion kit.

    This derailed an entire thread previously. There was no consensus. I believe yes. However in a true sealed system the original modules with their plenums should perform better. But that's not how the OE enclosure is setup. Also since the modules are thicker (diameter of cylinder versus thickness of module) the heat will take longer to get from the deep inside of the cell to the outside. But this isn't a microwave where things heat up in the center, things usually heat up relatively evenly in a battery so again I don't think there is any negative effect and the net benefit is a positive. But my official answer is "we don't know".
     
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  16. Fredsimm

    Fredsimm Active Member

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    We have been hoping for a viable long term alternative. I really hope this test goes well and I hope this business of yours is successful with the addition of the kits.
     
  17. kenoarto

    kenoarto Senior Member

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    Corrections to hype from Original Post:
    This is a terrific sounding, experimental DIY kit designed to replace a Toyota Prius Hybrid Battery (a.k.a. HV, High Voltage Traction Battery). It is delivered in several packages with brand new battery modules, bus-bars, battery wiring harness, and interconnects. DIY install will take 4 hours or more. Professional installation hasn't been tried yet. You retain all of your original battery cells, metal enclosure, and hybrid ECU.

    Theoretically Superior, Experimental Design-- recently being tested in the inventor's own Prius for the last few months
    Cylindrical cells with half the battery modules, promised to have the same functionality.

    Warranty from inventor
    A 2 year or 25,000 mile warranty on the modules.​

    How Much?
    For $1600 and approximately 4 hours of installation time, you wget a brand new hybrid battery backed by the inventor's 2-year/25,000 mile warranty. A similar design is available from Craigslist and/or Alibab.com for $900.

    Doing the Math
    This battery is a very exciting new choice for an older Toyota Prius needing a Hybrid Battery pack replacement. Alas, the cheaper, rebuilt batteries are having a high number of reported failures. The genuine Toyota battery used to be the only and very expensive solution, but the price has come down dramatically.

    Prices listed below are what you will pay. At a genuine Toyota dealer, you will also be charged a fully refundable $1350 core exchange fee, that you get back you return your old battery back. FYI: Some Toyota dealerships are hesitant to sell the average consumer a hybrid battery at the parts counter, but Prius chatters have found several friendly dealers have across the country.
    • Genuine Toyota battery
      • $2000 - This is a brand new Toyota battery, using genuine original parts picked up at a dealer without installation.
      • $1350 refundable core deposit required if DIY. Note: no warranty if DIY
    • FULLY INSTALLED genuine Toyota DEALER (INCLUDES 3 YEAR TOYOTA WARRANTY!)
      • $3000 - This is a brand new Toyota battery, using genuine new parts from at a dealer with installation. This is the average price you will be charged.
      • No core deposit charge required
    • Aftermarket experiment NewPriusBatteries.com (with 2 year warranty from a tiny, one-man company)
      • $1600 - This is a brand new, experimental design, untested, aftermarket battery, using a special kind of new module. DOES NOT INCLUDE INSTALLATION.
      • There is NO core charge, and you keep your original Toyota battery.
      • Free shipping within the continental USA!
      • We do not know who will install this for you. We will not install this for you. $600 has been paid by other Prius owners for other pack installs made by Toyota.
    Standard Installation Flow
    These kits may be more difficult to install than a standard battery swap. Dealers will not install this kit.

    Less than $2000 is awesome for a genuine, new Toyota pack. This experimental/untested new design is $1600. Question is whether this early risk/experiment worth saving $400 to needy Prius drivers. Only time will tell if this new design works and lasts.
     
  18. 2k1Toaster

    2k1Toaster Brand New Prius Batteries

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    Again, stop spreading lies and maybe listen to what is said.

    A "similar design" available on Craigslist or Alibaba is akin to "you can get a Honda Insight which is a similar design as what you'd get in the Prius, obviously they're the same". FALSE.

    Also, please get me a quote where you can order the "similar design" packs for $900. The CEBA packs are listed at roughly $900 USD plus $300 to $400 shipping costs to the USA plus import taxes and fees. They also come with no North-American based warranty. I ordered a CEBA pack long ago, total cost delivered to the door was about $1300. So your claim of $900 equivalent, FALSE.

    Again, get me a quote for $2000 Toyota battery. It can't be done unless you know someone. Claim of $2k original battery, FALSE.

    My 2 year warranty is backed by my battery factory. A huge hundred-million dollar a year factory of which I am a customer and have been for quite some time. Also my "tiny one-man company" may be true, but that doesn't mean I am new to business in general. Not false, but misleading.

    $600 has been paid for installs, $400 has been paid for installs. There's a local craigslist guy who advertises $200 installs. I am sure some idiots have paid more as well. Not necessarily false, but just STUPID.

    How the heck do you think these are "more difficult to install than a standard battery swap"? Ever done one? No? Everything lines up the same. I already walked a customer through installing one and with some guidance he was able to do it without problem. Once the full manuals are designed and printed, should be no additional guidance required. It is the exact same level of difficulty as a battery module swap. Because this is what it is. You are literally swapping battery modules. Your claim, FALSE.

    I have no idea why you insist on spreading this stupid crap. But leave this thread immediately unless you have something constructive to post. Your post has been reported.
     
  19. kenoarto

    kenoarto Senior Member

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    What will you charge to install?
     
  20. kenoarto

    kenoarto Senior Member

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    Dude, you need to be completely honest. Customers need to believe you, but you are fudging the facts. And then you get belligerent when you get corrected with facts.

    I can only imagine a poor customer trying to get you to honor your warranty without you flying off the handle and calling them wrong and/or stupid.

    2005 Toyota Prius Parts - Battery - G951047031
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    2005 Toyota Prius Electrical Parts & Components battery Battery - OEM Toyota Parts

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    #20 kenoarto, Oct 19, 2017
    Last edited: Oct 19, 2017
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