I just bought and installed brand new hybrid battery (part G9510-47031) from Toyota for my Gen 2 (2005) Prius. Oddly, the new replacement battery housing lacks threads to attach the right side battery bracket to the battery whatsoever. The original housing had nuts welded to the inside of the case to secure the bracket to the battery. The new part just has holes there without any thread or backing. The service manual shows seven bolts total attaching the right "battery bracket reinforcement". Four of these are meant to thread into the battery, but the new battery housing has no way to actually attach it to the reinforcement bracket. I already returned the old battery for the core deposit unfortunately.. How is the newer battery meant to actually couple to the bracket?
Suspect it's a manufacture defect... You could weld a nut on the backside to make it as good as new, or just ignore it. And I may be the kind of person that wants a bolt in every bolt hole no matter what, but I've worked on way too many Prius that previous battery workers didn't use most of the bolt holes because there's so many of them and the customer will never know. Not that I approve of this, but you won't have an issue if you skip this bolt hole.
What a bunch of rookies....... You should install the side plate that goes on the end of the HV battery, since the side plate is what has the threaded inserts welded to it, not the main battery cover. This is the part that needs to be installed: 74427-47030 Genuine Toyota Bracket, Battery Carrier Catch (toyotapartsdeal.com) PS....when I do a battery job, I always have enough spare parts like threaded fasteners, plastic rivets, supplies to butt splice the wires at the fan, etc so I can correct any deficiencies I find during the install. Even a tap to fix cross threaded mounting bolt holes. I also bring a spare cooling fan with me because it's faster to swap one than to try to clean a nasty one.
and just to add to that, the end plate is what holds the white plastic tube that the rubber vent tubes attach. Then another rubber tube attaches to the plastic and vents out the floor of the car. The square hole shown in the photo should have a small white plastic insert that pops into it that holds/aligns the side plate. Apparently the rubber tubes/etc did not get moved to the new battery. Not really needed, but this is a prime example of DIY starting to go wrong. Hopefully the other more important pieces got transferred over. Leaving out pieces during the swap can greatly affect how cooling air flows through the battery and then the customer gets all bent because the battery runs hot or starts getting temp alarms. See this oldie.... Really Bad Battery Repairs | PriusChat
Oh... That side of the pack. Was thinking this was the other side... And yes, I do the fan swap routine rather than clean. And many Toyota Stealerships just charge the customer $400 for a brand new fan because they think cleaning something is beneath them and the stealership owner is like whatever it takes to sell as many overpriced parts as possible.
Thank you! Just ordered a new bracket. That sounds like a good explanation – I was surprised that the housing would have changed, must have forgotten to transfer the part over from the old pack. I did transfer the venting tubes to the battery modules and connected the hose to them in the vehicle, so hopefully everything else is correct for the venting and cooling. I'll take a look when the part comes in.
My personal preference is to just deal with the core charge for a few days. I keep the old pack until everything is transferred over and the new pack is installed and working. Then return the old core. Posted via the PriusChat mobile app.
The price is high but it may make sense to change the pack fan on a ~14 year old car while it is easily accessible. The junkyard fan I bought to mess around with had an awful lot of what I thought was graphite powder (added by a user for lubrication) fall out of it. Now I think it was more likely dust from worn down carbon brushes inside the motor. I have yet to figure out a way to get the motor apart (impeller seems to be permanently attached to the shaft) so I cannot look in and see for sure, but if it is actually a contact motor the brushes are going to wear out eventually, and since taking it apart to replace the brushes is to first order not possible, not a terrible argument for replacing the fan at that age.
