Hybrid Battery Module Fault is Pending. Wait Till Current?

Discussion in 'Gen 2 Prius Main Forum' started by Omar Haddad, Aug 9, 2025 at 2:05 PM.

  1. Omar Haddad

    Omar Haddad Junior Member

    Joined:
    Jun 8, 2021
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    Location:
    Sag Harbor, NY
    Vehicle:
    2006 Prius
    Model:
    N/A
    Hi everyone,

    I have been getting different error codes for different modules in the hybrid battery, some of which I knew were okay, so I replaced all the connectors. Now I am getting a pending fault on a couple of blocks (5 and 9). I tightened the connector nuts but not too much. The faults are not current but pending. Is it worthwhile to wait to see if the faults disappear on their own? On one of the modules of block 5 it was difficult to put the nut in. It was tight as soon as I would screw it in, so I know I will replace that module with a new one. But I've done this at least 6 times for the past month, and I've been getting erros on different modules seemingly at random. Is there something obvious that I might be missing?

    Thank you.

    UPDATE: It seems that the pending fault was because the nuts were not tight enough. In an effort to avoid overtorquing the nuts after replacing the bus bar connectors, I left them minimally tight, but I would guess the vibration of the car would loosen them, causing spikes in voltages in specific blocks. That would explain why the errors would happen at random and on modules that I knew were okay. It would also explain why on the highway the errors would be more likely: the vibration is greater at higher speeds. I only tightened up the nuts on all four modules in blocks 5 and 9, and I haven't got an error so far. If I get another error, I'll simply tighten the nuts on the modules that trigger the error. I won't be replacing modules. I hope this helps somebody.

    Thank you.
     
    #1 Omar Haddad, Aug 9, 2025 at 2:05 PM
    Last edited: Aug 9, 2025 at 7:58 PM
  2. Omar Haddad

    Omar Haddad Junior Member

    Joined:
    Jun 8, 2021
    27
    3
    0
    Location:
    Sag Harbor, NY
    Vehicle:
    2006 Prius
    Model:
    N/A
    Here are some photos
     

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