Lots of questions, if you can answer any that would be great.

That is normal when the pack is going out. How was it "rebuilt"? New modules, old ones?

 

Pretty normal stuff clunking lower arms the rubber circle bushes that push into frame . Any components utilizing these type bushes they all broken now take a look . To check suspension requires a long iron bar like digging bar with that bar you can spread those bushes by tweaking on lower arms etc side to side up and down etc . The front end and frame shops are quite man handeling you vehicle whilst doing . You'd be very upset. To see it maybe.

 

Battery been addressed . Dump some good fuel on top of junk or hose in tank get old out . Fill it if you gonna drive it .

 

Have you checked your air filter? Cleaned the MAF? Try force charging the battery by putting car in Drive and pressing both brake and gas pedal at the same time. The SOC should rise to 3 blue bars in short order. I have replaced the arm rest and center console with vinyl fabric I got at a local shop. I bought some premade arm rest covers off ebay and spray glued them on to the plastic armrests. You will have to drill out the melted plastic rivets and when you put them back use short screws with a wide head.

 

Do you have techstream? It will enable you to look at the current/power limits being imposed on the HVbattery for charge and discharge. Some phone apps will also do it.

At low and high temperatures (and low and high states of charge iirc) the car will limit the power going into or out of the battery, but not provide any indication of an alarm or warning.

This is usually displayed in kw as and will be a (+) or (-) value

 

If you DIY, search "prius center console cover" on BezoMart and pick the fabric style and color. Pretty easy to do if you remove the console top. The screw to the latch release was a bit tricky to remove. I replaced the thread bare leatherette with a synthetic leather material in black so the elbow dirt didn't stain as easily as on the original beige cover. I used contact cement. Some covers include double sided adhesive tape. The cover I bought was under $5 off of Aliexpress pre-tariff era.

 

There are a few companies on the Asian sites that have this piece pre-made

 

Two years ago and then it sat. The pack is probably pretty far out of balance from just sitting that long with a set of modules which are different ages, different amount of use, different amounts of dried out, basically just not perfectly matched. Use Techstream of Dr. Prius to check how close the module voltages are.

Toyota does make new modules for this pack, unless they stopped very recently. Buying a replacement set will cost $2k-$3k(ish) if you install it yourself.

 

Try MTG

 

The fan should be running in 102° weather that means it's 140 in the car till you blow that out put on air etc .

 

That's pretty normal to stay blue with the air conditioning running and good driving . It's not just battery overheating that . It's a combo of things going on . Inverter temps . Is pump. Running full resi etc the heat taxes everything electric. All the time even in ice car

 

I do not physically know the answer to that at all I Iwould say 120 plus . But then that's likely to trigger the hybrid system not charging inverter cutting power etc to save system .. I'm running in similar temps last 4 days . No issues at all all three being driven . In this heat I keep it to 65 ish AC on lo med hi fan and enjoy the cool drive . Not trying to kill it .

 

Record it and post it.

If the fan isn't working right the pack will warm up and then the computers will tone down its use to prevent further overheating. Have you checked that the pack fan is clean, the air inlet isn't plugged up with dog hair, and that it can run fast and slow? The connector sometimes gets corroded when there is a leak from near the hatch hinge - water runs down into the electrical connector.

 

Is the hybrid fan dirty? Check the duct work mine wasn't sealed very well at the connections so I added HVAC Tape over the seams to increase air flow. That helped a lot. Maybe your fan seized up? I'd visually check the air flow at the battery.