Replacing the hybrid battery with a new Toyota battery

Discussion in 'Gen 2 Prius Care, Maintenance and Troubleshooting' started by Deadbeat, Sep 6, 2017.

  1. Deadbeat

    Deadbeat New Member

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    I'm replacing my hybrid (traction) battery with a new battery that I purchased from the Toyota dealership. There were other options, but this was the right one for me.

    Anyhow, I removed the battery from the car. Fortunately, one of our PriusChat members pointed out that I will need to 'migrate' some of the hardware from the old battery case to the new battery that I am purchasing (vent tubing and electronics?).

    Does anyone have instructions, a YouTube video, or a description of what hardware (and how!) I need to migrate? I found instructions for a 2010 prius in the PriusChat forums.

    ...but they are for a 2010 Prius, and the instructions and pictures deviate at some point from my own gen 2, 2006 model. I've tried online searches, but none of the search hits are for replacing the hybrid battery with a NEW battery.
     
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  2. Mendel Leisk

    Mendel Leisk Titanic Social Director

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    When you've got the old and replacement battery side by side, doesn't it become apparent what needs to be transferred over? Or is it not that obvious? (n)

    Does doing DIY install reduce the warranty period? I'm thinking from three years to one, IIRC? Did you get a quote for installed?

    Myself, even though I think I could DIY, I'd probably let the dealership do, for the warranty extension, and peace of mind.
     
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  3. Deadbeat

    Deadbeat New Member

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    Ummm. No.

    For a pro like you, I'm sure this is an easy job. For me, it is the first time I've removed and then replaced a hybrid battery. I could just yank it out and eyeball the parts and line them up. Sure.

    But for me at least, a guide or set of instructions are helpful both to speed the task up and also avoid unanticipated pitfalls. I would prefer to use the best information available to complete the task. For example, another PriusChat user noted that the nuts on the terminals have to be tightened to a very specific torque. Good to know, and not something I would have known just looking at the device.

    For anyone reading: do you have a favorite link or resource for this task?
     
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  4. Deadbeat

    Deadbeat New Member

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    For reference: here are pictures of the old hybrid battery and the new one, in its packing. (As an aside, the freight packing that Toyota uses is so large that you had better have a van with the seats down or a pickup truck when you pick up from the dealership)

    Once you remove the cover on the new battery, the vent tubing is an obvious transfer from the old battery.

    The electronics on the left side of the old battery also need to be moved.
    IMG_1817.JPG IMG_1823.JPG
     
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  5. jadziasman

    jadziasman Prius owner emeritus

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    Everything (well almost everything) you will need to know is in the service manual in the HB - P112 Hybrid Battery Control section for the Gen 2. PM me and I will provide you with that section for your swap. Or you can do a Google search for that section and maybe you will find a site that you can download it from for free. It used to be available several years ago.
     
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  6. fotomoto

    fotomoto Senior Member

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  7. jadziasman

    jadziasman Prius owner emeritus

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    I may be incorrect but I could not find the section Deadbeat needs in your link.
     
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  8. ericbecky

    ericbecky Hybrid Battery Hero

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    Have the two batteries side by side and it will be obvious.

    Take some pictures to remind yourself.

    Go slow. Allow yourself plenty of time. Don't wait for Sunday night to start if you need to be to work on Monday morning.

    For goodness sake unhook the 12v battery when doing the work. Use your volt meter to check the high voltage leads for voltage before putting your hands in them. I would like to imagine you'll use high voltage safety gloves, but if you are like most folks you won't. (shrugs shoulders). I like to think most people think their lives are worth spending $50 to protect, but I've seen time after time that I am wrong.

    Use ALL of the NEW parts Toyota gives you. The nuts with washers. The nuts without washers. The leads. The black plastic cover. The foam pieces.( Notice that they are different and go on specific sides of the pack.) The fuse holder.

    Don't decide that you know better, and decide you'll just use "some".

    Be sure to return the old battery core in similar condition to the NEW one. (with the addition of the 2 brown rubber mats) Remove the old orange leads off of it and wrap the harness similarly to how you received the new one.

    Be sure to correctly seat the bug orange plug once everything is back together. Practice it outside the car a few times to get the feel of that final "click" when you slide it downwards.

    Feel free to call if you need some help during the week.

    Forgot that this is a 2010. Some of the parts will be different. Still, you will be able to figure it out. Lay out all the pieces
    Take pictures. That will help a lot.
     
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  9. jadziasman

    jadziasman Prius owner emeritus

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    The nuts with built in washers for the module terminals require 48 in-lbs of torque.
     
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  10. Deadbeat

    Deadbeat New Member

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    Well thanks everyone.

    I just eye-balled it and made the swap. Car fired right up.

    I wasn't able to find an instruction manual online. Maybe my Google is broken.

    I have to say, it would have been easier with a guide or instructions to cut down on the redundancy, and double checking a bunch of pictures I had to take, but even my crude methods were enough.
     
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  11. VFerdman

    VFerdman Senior Member

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    Good work, don't doubt yourself. This is not rocket surgery. Hope you have good results with this!
     
  12. Deadbeat

    Deadbeat New Member

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    I know everyone says it will be obvious, but I guess I'm a bit dull there.

    Looking at the Prius manual, they even have detailed instructions for changing your nav display or even a tire! There is far more at stake with the traction battery. I prefer a good video or instructions, but whatever it totally worked out. Thanks jadziasman for offering telephone support. What an awesome community here!

    I am guessing from the dealership's reaction that an owner replacing the traction battery on their own is not common. When I showed up earlier today to get the battery, I was met by the service manager who indicated they weren't even sure they were allowed to give me the battery I had ordered. I had to listen to an electrocution lecture for a while before they let me take it.
     
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  13. dolj

    dolj Senior Member

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    As the HV battery is not intended to be a user serviceable part, there will be no mention of it in the user (owner's) manual.

    I know it is a moot point for you, but I will mention it anyway for future readers.

    You can download the hybrid battery section (as detailed in jadziasman's post #5, or, in fact, any other part of the repair manual, new car features manual, or electrical diagrams manual, for that matter, from Technical Information Service (TIS – techinfo.toyota.com), by creating an account and then taking a two (business) day subscription. You can then download anything you desire while your subscription is active. This includes the exact same instructions a Toyota tech would have to do the HV battery install.

    I didn't mention it before as by the time I got to the thread you had already completed the job. So, I hope that helps someone in the future.
     
    #13 dolj, Sep 7, 2017
    Last edited: Sep 7, 2017
  14. Deadbeat

    Deadbeat New Member

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    Thanks! Will keep that in mind for my future endeavors

    I didn't catch a lot of these replies until I was done either.
     
  15. 4priusowner

    4priusowner Junior Member

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    I just finished doing this and I will be uploading a video shortly after I edit it but it wasn't as hard as you may think.like they said once the batteries are side-by-side you can pretty much see what has to be changed over and then the install or taking out the battery is already on YouTube so I will be uploading my version of the swap out on a brand new battery.

    Posted via the PriusChat mobile app.
     
  16. ericbecky

    ericbecky Hybrid Battery Hero

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    As I ask all folks, you used an inch-pound torque wrench for the connections, right?
    Tightening "until it feels about right" is a bad idea for HV and voltage sensing connections.
     
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  17. HT12

    HT12 New Member

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    Hi everybody, first time posting!

    Recently was able to find a New Toyota Prius Battery direct from dealer for $1689. Hoping to do the install myself, but wondering if anyone has documentation of different torque specs. Can't seem to find them.

    Also in the case of finding a battery so cheap, is it worth just having the dealership install for the extra 2 year warranty?

    Thanks so much!
     
  18. HT12

    HT12 New Member

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  19. exstudent

    exstudent Senior Member

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    If only their labor rates for this job was reasonable. Then maybe.

    Matt @Texas Hybrid Batteries, isn't a Toyota dealer but has been installing NEW geunine OEM Toyota HV Batteries w/ a 4 year warranty on him! He is taking a 3year gamble (years 2-3-4), that a failure will NOT happen. That's confidence, and a low risk gamble.
    Texas Prius Battery Replacement
     
    #19 exstudent, Jun 5, 2019
    Last edited: Jun 5, 2019
  20. Mendel Leisk

    Mendel Leisk Titanic Social Director

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    Torque info starts around page 82. Be careful: some are inch/pounds, which you would divide by 12 to be foot/pounds, if needed.
     

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