Lost part while trying to reinstall my HV battery.

Discussion in 'Gen 2 Prius Care, Maintenance and Troubleshooting' started by KnightofNi1, Sep 18, 2025 at 2:06 PM.

  1. KnightofNi1

    KnightofNi1 Junior Member

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    Hi All

    I had a few cells go bad on my 2004 Gen2 HV battery.

    Between some wonderful YouTube vids out there and these amazing boards, it was pretty easy to follow and get them replaced.

    My issue is that I had to take a little bit of time off after replacing the cells and managed to misplace a part in between.

    I am by no means an expert so I have no idea what the part is called but it's essentially a bracket that sits between where the orange cables connect to and the metal case that goes over this section of the battery.

    IMG20250918125431.jpg IMG_20250918_133744.jpg IMG_20250918_133953.jpg

    Does anyone know what that shiny silver bracket is called or have a diagram with the part number on it so I can order one?

    If that's not doable, does anyone know what thin bendy material it's made from? I could probably fashion my own .

    Thanks in advance for any help provided
     
    #1 KnightofNi1, Sep 18, 2025 at 2:06 PM
  2. dolj

    dolj Senior Member

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    It is PNC 82675C - TERMINAL, JUNCTION

    Part number 82675-47080
     
    #2 dolj, Sep 19, 2025 at 1:18 AM
    KnightofNi1 likes this.
  3. KnightofNi1

    KnightofNi1 Junior Member

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    Thank you so much!
     
    #3 KnightofNi1, Sep 19, 2025 at 1:37 AM
  4. dolj

    dolj Senior Member

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    No Problem.

    FYI, in the second photo above, that part is shown being installed upside down. The two dimples should contact the wire shields, not roll over them.

    upload_2025-9-19_17-56-59.png

    This shows the correct orientation.
     
    #4 dolj, Sep 19, 2025 at 1:57 AM
    Last edited: Sep 19, 2025 at 3:13 AM
  5. PriusCamper

    PriusCamper Senior Member

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    You could probably make one with some thin metal... But I bet you find the one you lost if you remove the backseat bottom. They tend to end up down there when taking a pack apart.
     
    #5 PriusCamper, Sep 19, 2025 at 1:51 PM
  6. dolj

    dolj Senior Member

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    It's not worth it; they cost less than $3 to buy a new one.
     
    #6 dolj, Sep 19, 2025 at 11:31 PM
  7. PriusCamper

    PriusCamper Senior Member

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    Depends on your location and how much time, money and effort it takes to get that part... And this particular part is likely to make near zero difference if you install the pack without it, but I'll let @ChapmanF refine that.

    And I do have a couple extra and could mail one to OP for free if they send me their address....
     
    #7 PriusCamper, Sep 19, 2025 at 11:35 PM
  8. dolj

    dolj Senior Member

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    True, but I'm sure the OP can decide whether any of ths is a factor.
    It is an essential component that grounds the cable shielding. Do not leave it off. Also, ensure it is not installed upside down, as this would prevent it from providing the necessary clamping pressure for a proper ground.
     
    #8 dolj, Sep 19, 2025 at 11:48 PM
  9. PriusCamper

    PriusCamper Senior Member

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    While I have no reason to not include it, I bet that if we tested it without it'd be fine. My hunch is that its additional redundancy for pack failures. And I'm not remembering it being used at all on Gen3 Prius? I've not worked on as many Gen3 than Gen2 so not certain. And as always, I trust @ChapmanF 's opinion on this subject.
     
    #9 PriusCamper, Sep 19, 2025 at 11:54 PM
  10. dolj

    dolj Senior Member

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    Why speculate? Do the testing and report back.

    I'd be interested in your testing methodology. To test effectively, one would need to fully inform themselves about the design and function of the system. However, few people take the time to do this, so it often ends up as just one unqualified opinion against another.
     
    #10 dolj, Sep 20, 2025 at 12:02 AM
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