HV battery code! changed cells, cleaned contactor plates, problem still exists! help!

Discussion in 'Gen 2 Prius Care, Maintenance and Troubleshooting' started by shuiyuan, Jul 5, 2024.

  1. shuiyuan

    shuiyuan New Member

    Joined:
    Jul 5, 2024
    8
    3
    0
    Location:
    usa
    Vehicle:
    2005 Prius
    Model:
    ----USA----
    Hello everyone! im very lost here need help, i have helped friend's Prius changed battery cells before, always solved the issues, car ran great for years after i fixed it and recently my own car is having some issues and i searched and searched and tried everything problems still exists!
    1 month ago my 05 Prius started shut off the power system while driving due to bad battery cell codes, just like any weak and battery cell problems i understand Toyota is shutting down the power drive system and let the gas engine run only to prevent battery overheating issues.
    my car has CEL code P0A80, P3017, P3024, i checked every single battery module all had over 7.6V, i used DR Prius, Techstream , Torque pro, all shows every single blocks are 16-17V range when driving which is normal.
    things i have tried; swap good cells on Block 7 (p3017) and Block 14(P3024) , took all contactor plates on both side of the cells sanded and cleaned shows clear cooper color ,always reset CEL, as soon i drive, i can hear battery ECU is clicks 2 or 3 times then will click off the battery power system leaves the gas engine only and revving high , shut off the car and restart will last another 1-2 minutes then going to the limp mode again.
    any battery expert on here can have any comments or this happened to you?? please help!
     
    #1 shuiyuan, Jul 5, 2024
  2. Tombukt2

    Tombukt2 Senior Member

    Joined:
    Nov 29, 2020
    11,557
    2,030
    0
    Location:
    Durham NC
    Vehicle:
    2009 Prius
    Model:
    Base
    So is there a problem with intermittent charging of the HV battery Do you have regenerative braking working when you step on the brakes You see the blue lines on the display? The MFD little green turtle car is not red with an! And possibly the word problem across the top of the screen? When this happens and the gas engine is starting to run permanently and charging is turned off or the clicking you're talking about is stopped that sounds like relays in the back at the battery I'm not sure that those should be just clicking off while driving but that's another story. Seems like in TIS you would have some orange underscores to be looking at with all this going on I would be more concerned with what Toyota software says and any of the others so have you cleaned all the bus bars and nuts or just the ones on the modules that you're working on that could be seriously problematic I think you want to clean all the bus bars and nuts I know there's a bunch of them but you know nothing I can do about that. Some pictures of your work in this battery might go some distance.
     
    #2 Tombukt2, Jul 6, 2024
  3. bisco

    bisco cookie crumbler

    Joined:
    May 11, 2005
    111,575
    50,812
    0
    Location:
    boston
    Vehicle:
    2012 Prius Plug-in
    Model:
    Plug-in Base
    did you replace the sensor harness?
     
    #3 bisco, Jul 6, 2024
  4. mr_guy_mann

    mr_guy_mann Senior Member

    Joined:
    Sep 3, 2020
    3,921
    1,888
    0
    Location:
    NJ-USA
    Vehicle:
    2006 Prius
    Model:
    Four
    After your car sets codes, have you used Techstream to look at the freezeframe data? That should have a capture of the battery block voltages and show you what the ecu doesn't like.

    If any block is 1.0-1.5V lower than the others (often only when discharging), then you almost certainly have a failed module in that block.

    Posted via the PriusChat mobile app.
     
    #4 mr_guy_mann, Jul 6, 2024
    maleko likes this.
(You must log in or sign up to post here.)