Severe corrosion on HV cells and case

Discussion in 'Gen 2 Prius Care, Maintenance and Troubleshooting' started by E Priusmack, Jan 26, 2024.

  1. E Priusmack

    E Priusmack New Member

    Joined:
    Jan 26, 2024
    3
    0
    0
    Location:
    Auburn, GA
    Vehicle:
    2009 Prius
    Model:
    N/A
    Gen 2 Prius P0AA6-526-612
    Corrosion on almost every cell terminal on both ends.
    Corrosion below terminals on case.
    368 kohms, 140 volts with service plug disconnected
    The corrosion is on the nuts on each post. It extends to the wiring harness.
    Is there any hope for replacing just a few modules or should I assume that they all need to go? Could electrolyte have leaked horizontally across every post? It seems unlikely.
    I'm afraid to turn the nuts to test each cell. Could cells be destroyed by turning nuts-will the posts break off? If so, I can't be testing the cells because I need the car to get to work.
    Can I use cells from a gen 3 prius in my gen 2 case?
    When buying a used battery, what should I check out before buying? For example, serial numbers all the same, resistance and voltage. Is there a way to test load in the field when the battery is not installed in a Prius? What else should I be thinking about?
    Where can I buy a wiring harness (cheaper than the dealer)?
    What would have caused so many cells to leak? For example, should I be checking the cooling fan? I've heard it come on.
     
  2. PriusCamper

    PriusCamper Senior Member

    Joined:
    Mar 3, 2012
    12,794
    5,180
    0
    Location:
    Pacific Northwest, USA
    Vehicle:
    2007 Prius
    Model:
    Two
    Completely normal... NiMH is an oudated chemistry that no other automakers use anymore. It leaks at the seals and creates corrosion. Either clean it up periodically or buy from a carmaker that actually wants to advance technology rather than just profit from the past.

    Also make sure to look inside your ECU for corrosion and clean it or you'll get a P3000.
     
  3. Tombukt2

    Tombukt2 Senior Member

    Joined:
    Nov 29, 2020
    13,041
    2,336
    0
    Location:
    Durham NC
    Vehicle:
    2009 Prius
    Model:
    Base
    Go to a battery refurbishing place the green beans whoever whoever's in your area the hybrid doctor all of these places with the catchy names when you pull up to their places you will see battery cases stacked up as tall as you are they'll have plenty of parts walk in with what's burnt up hold it out even if they don't speak English they'll be right back with your peace so on and so forth they might even give them to you because they're trying to get this stuff out of there they have to call the metal man and all of this and that just to get this stuff removed or they have to do it themselves all those cases all those modules that are completely dead contactors relays wiring harnesses The orange and black plastic covers The guy where I go has so much of this stuff sometimes I go over there and load up my trailer and just take it to the dump form because I'm a nice guy like that whatever and he treats me right so no problem I ever need to contact her or relay or any of that shite I just pop up over there give him $10 and a Pepsi and off I go
     
  4. E Priusmack

    E Priusmack New Member

    Joined:
    Jan 26, 2024
    3
    0
    0
    Location:
    Auburn, GA
    Vehicle:
    2009 Prius
    Model:
    N/A
    Thank you, PriusCamper. I love your drawing. Does it mean to show that we (humans) are damaging ecosystems? I swore I'd never own a gasoline-only vehicle out of concern for the environment. I also appreciate your comment about Toyota's use of NiMH. So, tell me, do you think that Lithium batteries are a better choice for the environment? That would be a significant consideration for me but I haven't researched it myself.
     
  5. E Priusmack

    E Priusmack New Member

    Joined:
    Jan 26, 2024
    3
    0
    0
    Location:
    Auburn, GA
    Vehicle:
    2009 Prius
    Model:
    N/A
    Thank you, Tombukt2. I didn't even know to look for places in my area so that was a really good tip because I might be able to find one.
     
  6. Tombukt2

    Tombukt2 Senior Member

    Joined:
    Nov 29, 2020
    13,041
    2,336
    0
    Location:
    Durham NC
    Vehicle:
    2009 Prius
    Model:
    Base
    In Georgia you will find several places I'm not even sure where Auburn is per se but maybe down near Alabama. Shouldn't be an issue at all You don't have the yellow pages anymore so you'll Google that You want to find a shop that does hybrid battery rebuilding and repair not the green beans and the green tec and all that nonsense. My battery guy personally advertises on Facebook marketplace He's a millwright at a large meal here in North Carolina up on the Danville Virginia border and then he likes to build batteries for these hybrid cars and other projects like that for fun seriously so at his shop which is at his house out in his detached garage he has cases relays the orange wires all of this kind of stuff just stacked up that he really needs to get to the dump but between work and his hobby and goofing off the dump trips are few and far between so the shop like this would be perfect for you to go up and get what you need for reasonable because most of that stuff is actually headed off to the dump He's got way more than he'll ever need for parts etc.