1. Attachments are working again! Check out this thread for more details and to report any other bugs.

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

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

  1. edthefox5

    edthefox5 Senior Member

    Joined:
    Jul 25, 2007
    10,096
    4,806
    0
    Location:
    Clearwater, Florida
    Vehicle:
    2007 Prius
    Model:
    Two
    Thanks everyone for mentioning my post.

    Yeah the wires from the battery to the safety switch just did not lineup well at all. Or maybe I just got them backwards lol.

    I looked at them for a while and realized a modification of the angle of the connectors would make them reach/fit the battery's much better so I did just that I bent offsets into the 2 connectors of the wires at the battery's so they met the battery connector more squarely and it worked great.

    I had a picture of the connector angles I made but it has disappeared from my picture files. The issue is the closeness of the wires block the connectors ability to lay flush on the battery bolt. And the wires themselves in there stock configuration are very hard to bend to fit the new battery's so I used 2K's tip with a hair dryer to warm them up and bend the wires then bent offsets in both wire lugs where they attach to the battery. The covers did not go on without bending the connector but it was very easy no big deal.

    I did those 2 wires last and was getting pretty tired so some work around's happened lol.

    Still not sure if I got it right but did my best.

    But she fit good and was a beauty all bolted up.
     

    Attached Files:

    #961 edthefox5, Feb 3, 2023
    Last edited: Feb 3, 2023
    ColoradoCrow and drone13 like this.
  2. ColoradoCrow

    ColoradoCrow Active Member

    Joined:
    Sep 2, 2019
    973
    392
    1
    Location:
    Leawood, KS
    Vehicle:
    2008 Prius
    Model:
    I
    Thanks for the pictures. Looks like you also used Dielectric grease and buffed up your terminal bus bars as well. Nice work.
     
    edthefox5 likes this.
  3. edthefox5

    edthefox5 Senior Member

    Joined:
    Jul 25, 2007
    10,096
    4,806
    0
    Location:
    Clearwater, Florida
    Vehicle:
    2007 Prius
    Model:
    Two
    Thank you yes Redline CV-2 grease and the buss bars are new they come with the kit. I started cleaning all my old buss bars to later find the kit comes with new bars lol...

    CV-2 grease is the best stuff on the market 100% synthetic. Really good gun grease too. I put some in every electrical connector I run across on my cars. Stops corrosion and water ingress.

     
    kenoarto, mandichka and ColoradoCrow like this.
  4. nemebean

    nemebean Junior Member

    Joined:
    Sep 1, 2021
    42
    28
    0
    Location:
    Minnesota
    Vehicle:
    2007 Prius
    Model:
    N/A
    I ended up removing the side cover to rearrange the wires. Sticking my hand in there with everything place was losing me too much skin and didn't leave much room to move things around. Fortunately you don't have to remove too much trim to get at those bolts. I relaxed the bends a little, although there's just not enough space there to avoid some sharp bends. I did stick some adhesive weather stripping to the sharp edges, but if I had it to do over again I'd go with the approach in ed and Toaster's pictures and just modify the safety cover (which is not in place on either of those pictures) to let the cables come out the top. I'm planning to pull the tray out at some point and just see how the cables are holding up after putting some miles on it. If it looks like there's wear I can always pull it back out and reroute, but I'm trying to avoid having to open the whole thing back up.

    Aside from that, the battery is looking good. I've only put a few hundred miles on so far and it seems like the ECU is still adjusting, but watching the Torque gauges I can see it using the battery much more than it was. It will let me drive with the engine off a lot more than it used to and it's no longer trying to hold the battery at 65% SOC on the highway like it did when my old battery started to go. The average SOC has been creeping back toward 60 like it was when I first got the car. I assume that was the ECU trying to ensure the old battery didn't run out of charge unexpectedly.

    MPG already seems noticeably better, although I've only filled up once where I had an actual mileage to calculate it (I didn't realize I was going to lose my trip odometer when I disconnected the 12v). First tank was around 49, but we'll see if that holds up over time since as we all know the bladder gas tank can result in some weird single tank mileages. It does seems like the engine is having to rev less now that it's getting battery assist again though so I'm inclined to think MPG will stay improved. If I can keep getting near 50 in below freezing temps that would be spectacular!

    For reference, it ended up taking me around 6 hours total to do the replacement. That did include some not-strictly-necessary things like testing each module voltage just to make sure I didn't spend hours installing everything only to find out there was a problem I could have caught right away. Obviously everything was fine, but I'm glad I did it anyway. I also spent some time cleaning nasty stuff out from under the seats since I had access to that area. You can tell the previous owners had kids. I have three Lego people sitting in my garage now that I pulled out of that area. :)

    I also made a few mistakes, mostly things that were my fault for not reading directions carefully enough and not reading the whole directions before starting. I could have saved myself some re-work if I had known what subsequent steps were going to be. In particular I had to reroute some of the sensors wires because I didn't realize how that wiring harness fits in with the safety covers.

    Anyway, so far so good. We'll see how everything holds up over time, but based on what everyone has said previously I'm optimistic.
     
    kenoarto likes this.
  5. 2k1Toaster

    2k1Toaster Brand New Prius Batteries

    Joined:
    Feb 14, 2010
    6,035
    3,855
    0
    Location:
    Rocky Mountains
    Vehicle:
    2006 Prius
    Model:
    Three
    That's good news it's all together! You should see a boost in mpg, probably not 12+ though. As always, meter expectations over a few tanks. Things like the battery that get progressively worse over time sometimes surprise us with just how much of a difference it makes. Same with tires or alignments or even just dirty engines and filters. It doesn't prevent you from going. But everything has to work much harder for the same get-up. Engine works harder, sounds harder. Battery drains and wears more quickly. Fuel usage goes up. A high mileage vehicle always reminds you where that wear is. Fixing the battery is a major place to help out.
     
  6. qlak

    qlak Junior Member

    Joined:
    Sep 11, 2011
    29
    29
    0
    Location:
    NH
    Vehicle:
    2009 Prius
    Model:
    N/A
    I thought I updated all the post that talked about my situation with Newpriusbatteries. Guess I missed this one. I have not been on Priuschat lately.
    Drone13, thank you for your post. You said it better than I could.

    Thought this was over...take a deep breath.

    1. My point to bringing this public (spamming as he called it) was to get Nicks attention to my situation. l got NO RESPONSE to multiple request for a very long time. NO EXCUSES. He blames it all on my VPN. I called and left voice messages too. I sent personal messages here. I know he got my order because I did get ONE email from Nick, stating that "it would be another month". This was already pushing 90 days! I got no communication beyond that. He now talks about how quickly he responds to customers.

    2. What if I operated like Nick and had no proof that I purchased a $1600 dollar item? Do you think Nick would have heard my complaint? It is foolish to not have some kind of tracking to CYA.
    I am offended that he STILL thinks that my battery was stolen. Never his fault. No records....but stolen. Do not make that accusation unless you can prove that the battery was delivered! HOW DO YOU KNOW YOU LOST MONEY IF YOU HAVE NO RECORD FOR THE TRANSACTION? How much did you pay for shipping? Do you know you can write it off on your taxes? For the record, I live in a very rural area, with virtually no crime, on the end of a gravel road. Never had a single issue with items not being delivered.

    3. Nick said the order shows "delivered" but, when I logged in to my account on HIS website, the order said "awaiting fulfillment" last I checked January26ish?. I took a snapshot just in case. Where is the disconnect there?

    4. I never bashed Nick or his business. Where did I say to Nick "how I and my batteries are horrible"? I presented "Just the facts, ma'am". I have copies of every claim that I made. Even to the end I told everyone here to read the post and decide for yourself if you want to do business with this company? Surprisingly, I was still thinking of taking delivery of the battery. Its a good price...but what if something went wrong? That will never happen, right? (Sarcasm)

    5. I will end with this, Nick did refund my money "voluntarily" and this situation was "not something we did wrong." His words not mine.
     
    kenoarto and dpower like this.
  7. dpower

    dpower Member

    Joined:
    Mar 28, 2005
    97
    48
    0
    Location:
    Katy Tx
    Vehicle:
    2005 Prius
    Model:
    II
    Door it’s 6 months to reply, life go busy. it’s a NPB pac. Im pretty sure it’s toasted.
     
    kenoarto and bisco like this.
  8. dpower

    dpower Member

    Joined:
    Mar 28, 2005
    97
    48
    0
    Location:
    Katy Tx
    Vehicle:
    2005 Prius
    Model:
    II
    I’ve got at NPB and was part of this thread. I’m getting steady hybrid errors, I retourqed the pack at Nicks suggestion that showed up after I posted to his web page asking if modules were available, but I’m back to dead air. I resorted to trying my Maxx Volts grid charger to see if that might help the issue but still the same errors. As I can’t get any rational information using Dr Prius is it just time to dump it and look for a new oem pack. Has anyone run Dr Prius on his pack and gotten usable data out of it. I’d like to do a little troubleshooting but I’m disabled and there isn’t anyway for me to disassemble the pack again. As I’m out a usable core would putting in a lithium kit work? I don’t have the original cables and don’t know everything that’s included. I have a new to me 09 that’s in good shape and id a much higher trim level. I guess it’s back to the OEM battery for that one. At least it’s down to $2600 from the $4,000 when I bought the NPB pack.
    im always willing to do business with a new company as I started and ran a couple myself but I’m just not able to wrench it anymore. Two gen2s need batteries, I wonder what the solution will be.
     
    kenoarto and Tim Jones like this.
  9. bisco

    bisco cookie crumbler

    Joined:
    May 11, 2005
    108,888
    49,479
    0
    Location:
    boston
    Vehicle:
    2012 Prius Plug-in
    Model:
    Plug-in Base
    Lithium should work fine, contact them about the app. If you don’t get good communication now, you’ll never get it
     
  10. TMR-JWAP

    TMR-JWAP Senior Member

    Joined:
    Aug 12, 2016
    6,228
    5,911
    0
    Location:
    Columbia, SC
    Vehicle:
    2007 Prius
    Model:
    Touring
    The first thing I would do is inspect the voltage sensor wire harness and the ECU socket for corrosion. This is an extremely common problem and it won't matter jackcrap what modules are installed if there's corrosion issues in the ecu socket or the harness plug. The wire harness should be replaced, regardless. The ecu should be replaced if corrosion is present. The harness is available from Toyota for about $60 and ecus are available on ebay for about $75-100.

    I think the lithium battery may come with a new harness, but it still won't matter if the ecu side has corrosion.
     
    Brian1954 and jzchen like this.
  11. JC91006

    JC91006 Senior Member

    Joined:
    Nov 10, 2013
    16,482
    8,400
    0
    Location:
    Los Angeles, CA
    Vehicle:
    2008 Prius
    Model:
    II
    Do you have the part number for the harness?
     
  12. dolj

    dolj Senior Member

    Joined:
    May 14, 2012
    7,652
    3,865
    0
    Location:
    Wellington, New Zealand
    Vehicle:
    2007 Prius
    Model:
    N/A
    WIRE, FRAME, NO.2 (No. 2 frame wire) part number 82165-47040

    The MSRP is $89.96 but Olathe Toyota has it for $73.77.
     
    JC91006 and jzchen like this.
  13. TMR-JWAP

    TMR-JWAP Senior Member

    Joined:
    Aug 12, 2016
    6,228
    5,911
    0
    Location:
    Columbia, SC
    Vehicle:
    2007 Prius
    Model:
    Touring
    dolj, JC91006 and jzchen like this.
  14. donbright

    donbright Active Member

    Joined:
    Feb 17, 2018
    241
    150
    33
    Location:
    oklahoma
    Vehicle:
    2007 Prius
    Model:
    Two
    i have data from an NPB pack installed on a 2007 in 2019 (did not use DR Prius, used Torque, but should be the same info), its all online here.

    https://treecricket.com/vehiviz/
     
    Tim Jones likes this.
  15. Larryy

    Larryy Active Member

    Joined:
    May 27, 2017
    104
    113
    0
    Location:
    florida
    Vehicle:
    2007 Prius
    Model:
    N/A
    I have a problem revisiting me, my New Prius Battery is not cutting the mustard any longer. It was half the price and it lasted roughly half the life of an OEM. I'm still using it but I have an old cell phone with Torque Pro permanently hanging on the storage compartment door under the radio so I can reset the Hybrid Battery OBD codes on the fly to keep it out of limp mode. It doesn't happen much while running at highway speeds, but as soon as I slow down they pop one after another. Aggravating, because it happens most when in traffic.

    It's a solid rust free Florida car so I'd hate to junk it. I'm back in Michigan and looking for a used pack from a wrecked or rusted northern gen 3, any tips are appreciated.
     
    kenoarto and donbright like this.
  16. Brian1954

    Brian1954 Active Member

    Joined:
    Jan 31, 2021
    819
    305
    0
    Location:
    South Central PA, USA
    Vehicle:
    2011 Prius
    Model:
    III
    What codes are you getting and resetting?

    Posted via the PriusChat mobile app.
     
  17. Larryy

    Larryy Active Member

    Joined:
    May 27, 2017
    104
    113
    0
    Location:
    florida
    Vehicle:
    2007 Prius
    Model:
    N/A
    P3019 and P3021 which are Hybrid Battery blocks becoming weak, and very occasionally, P0016 Cam Crank Position Correlation.
     
  18. alftoy

    alftoy Senior Member

    Joined:
    Mar 16, 2009
    1,132
    509
    0
    Location:
    Saskatchewan, Canada
    Vehicle:
    2008 Prius
    Model:
    Base
    Source complete set of nimh modules from a 2020 Corolla for $900, unfortunately unless you have the harness and misc from your original OEM battery, you will have to source those or buy the harness from Toyota or a salvage yard. Maybe someone on PriusChat can assist you, maybe @TMR-JWAP can help.

    Search on car-part.com for 2017 Prius battery
    2020 Corolla nimh battery on car-part.com, Lansing MI zip, select NIMH.

    2017 Prius battery.jpg
     
  19. Larryy

    Larryy Active Member

    Joined:
    May 27, 2017
    104
    113
    0
    Location:
    florida
    Vehicle:
    2007 Prius
    Model:
    N/A
    Thank you so much ALFTOY. I kept everything when I swapped to the NPB. All I need is good modules.

    I would really like to know how you searched those results; website?, program?
     
    donbright likes this.
  20. Larryy

    Larryy Active Member

    Joined:
    May 27, 2017
    104
    113
    0
    Location:
    florida
    Vehicle:
    2007 Prius
    Model:
    N/A
    Does anyone know which other newer hybrids use the same modules as the second gen Prius, and the same quantity (28)?
     
    donbright likes this.