red triangle of death

The only times I've had that problem were when the positive terminal coming out of the pack into the relay slipped down under the other wires and pack wasn't hooked up because I didn't check my work. It's only happened to me twice after doing it 30+ times, but as I always tell people, there's near 100 electric connections you have to make for the pack to work after you've taken it apart and it's easy to miss one if you aren't super careful and recheck your work as often as possible.

At the same time, we still don't know what the error codes are, so it's hard to say what's wrong, but you do have your next bad module that's been taken care of and I assume you know your replacement module checks out via load testing, right?

Sounds like you have to decide between wating for your code reader to arrive versus pulling the pack and rechecking everything. Let us know what you decide and what the problem is once you know.

Also have you done any reconditioning on your pack?
BU-807: How to Restore Nickel-based Batteries – Battery University

 

Amy chance you reversed polarity of one of the modules?

Did you thoroughly check the condition of the crimp connections and ring terminals of the voltage sensing wires. Including the ones under the positive and negative leads? Often there can be corrosion or breaks in the wires or ring terminals.

 

sounds like a good idea. otherwise, you're gonna have to invest in dealer service or tech stream.

 

What app are you using with your OBD2 reader? Most OBD2 apps are designed for non hybrid cars and can only read engine ecu errors, not battery ECU errors... Try Dr. Prius app, it's designed for your car and can read battery ECU and subcodes.

 

You got to really called the salvation army then.
You just did sack a mole approach. No load testing the modules, nothing. No balancing them, putting a module just like that? It won't work.
However, have you checked the small receptacle connector by the service safety plug, if its socketed properly?

 

You need Techstream.

 

Yo daddy...

Although you have verified the safety disconnect is fully installed..(all three steps) the car may still think it's not installed. I'm sure you're asking.......How can that be?

Many times, when less experienced owners rebuild batteries, they forget something. What is that something? Take a look at the 3 connectors that connect the car's harness to the HV battery. You'll have a small, medium and large connector. The large connector plugs into the ECU. The medium connector plugs into the 12v control circuit for the relays, etc. That leaves the small connector. It plugs into a receptacle near the top of the case kind of above the safety disconnect. I'm sure that's fully plugged in, but where does that little wire go inside the battery? It has another plug on the other end that plugs into a receptacle at the bottom of the safety disconnect. When you perform the 3rd step of the safety plug install (push straight down) the handle will slide downward about 3/8 inch. This pushes a shorting wire across the terminals in that plug, providing the actual indication that the plug is fully installed. Many people forget to plug in this small wire at the bottom of the Safety Plug housing when they reassemble the battery. If it gets forgotten, the car still thinks the safety plug is not installed. Check it out, my brudda. Maybe it will be something this simple.

Now, if that doesn't help, you can also look at the electrical plug/socket mounted on the HV battery cooling fan bracket. My understanding is the Safety Disconnect wires run through that plug also. That plug can be exposed to water leakage/corrosion from moisture leaking around the hatch (sometimes resulting in water in the 12v battery area).

Hope this helps.

 

Not just the less experienced, but even the experienced, especially if they're working on your car while you ask them endless questions at the same time. There's near 100 electrical connections that have to be correctly made and if you miss a step or get the sequence out of order it ain't gonna work. Ya gotta be super focused and check and re-check everything because it's easy to lose track of where you're at.

 

1-800-kars-for-kids

 

Please everyone, don't ever support this incredibly disonest organization. They spend less then 5% of the revenue they generate on kids and that 5% goes exclusively to a private religious camp for Jewish kids that charges parents money for the kids to attend.

This crooked operation has been fined by both the State of Oregon and Washington for false advertising and they're spending the 95% of their revenue on real estate speculation and insane salaries for their leaders. And perhaps worst of all, they're so damn cheap that the little kids singing in that god-awful radio commercial are now 30 years old and they still haven't updated the ad yet. Every time I hear that radio ad I turn the radio off! This is the least deserving car donation charity there is. Don't support them in any way!!!

 

the ads drive me crazy, i have to shut the radio off.

i don't understand how they get away with it, when the ads are part of the radio stations public service announcement requirement.

 

First of all, good luck on your pending colonoscopy... Lol...

But more to point... Congratulations, you've passed the final initiation of hybrid battery repair!

There are so many steps involved in properly assembling everything without a single oversight... There's over 100 connections that have to be properly made for the rebuild to be a success.

IMHO Prius hybrid experts are people who have endured great suffering to become an expert. And the mistakes, oh geez the mistakes that can be made along the way. I could go on and on with stories!

 

So what your saying is you were living in your own private Idaho?

 

To fully enjoy the feeling of accomplishment on a project you must go through the pit of despair. You know, that point in the project where you wonder why you ever started it, and that you are sure that you will never complete it.
Because once you get past the pit and finish the project, you feel better than if it would have been straightforward and easy.

 

And that my friends is why Hybrid battery work can be so enjoyable!!! It's kinda like going to the gym
too often and destroying yourself to the point that you can't remember when you weren't sore, only to eventually realize that you're stronger than you ever thought you could be!