Refurbished Battery pack failing again

From I what I see that block2 is the one need replacement which means two modules,

Yes, each block consists of 2 modules, but it's typically only one module that fails and causes the voltage to be low.

but I am concerned about how High voltage charge is reaching on each block, is that normal.

Your voltages look pretty normal to me for the year. The highs and lows are going to vary considerably depending on whether the HV battery is in "discharge" or "charge".

Another question is I saw a thread that someone managed to use 4th gen modules 2nd gen Prius is it only modules he changed ?

Yes, the Gen 4 modules (Gen 3 also) are physically interchangeable with the Gen 2 modules. If you decide to install Gen 4 modules, you should do all 28 modules. You should also purchase a new 'wire frame #2' from Toyota. This is the wire sensor harness and busbars that fasten along the module terminals.

 

I see 100% SOC at the bottom of a couple of those screenshots. I'm thinking that cannot be correct. Force-charging to that level would not be advisable for battery longevity.

 

When you say refurbished, a DIY, or a third party?

 

Only replace with gen4 modules of the same chemistry (NiMH), as there is also a Li-Ion battery option available as well.

Disassembly And Breakdown Of The 2017 Toyota Prius Li-Ion Battery Video

 

... also, ensure the Gen 4 modules are NiMH and not Li-Ion. Although, if it came to it, I don't believe the Li-Ion modules could accidentally be used. I believe they are a different form factor. But it will scupper your plans.

[EDIT] SFO beat me to it.

[EDIT2] @SFO, Thanks for linking to that Weber U Disassembly And Breakdown Of The 2017 Toyota Prius Li-Ion Battery Video. Very interesting.

 

There are two battery models for Prius G4, one is total same with Prius G2/3, another one is Lithium battery type. a

After getting the same material, you may need to match the parameters of voltage and capacity, make sure to keep Voltage, capacity, and internal resistance inconsistency. So that to prolong battery life. Otherwise, may come to an end soon again.