Post Battery Refurbish Issues

Discussion in 'Gen 2 Prius Care, Maintenance and Troubleshooting' started by trevansg, Dec 9, 2025 at 4:03 PM.

  1. trevansg

    trevansg New Member

    Joined:
    Oct 12, 2025
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    Location:
    Provo UT
    Vehicle:
    2005 Prius
    Model:
    Base
    Okay, so i could really use some help from you experts with finishing my hybrid battery pack repair. I made a few posts on this forum previously in ignorance that were poorly informed and i have since done a lot more research and a lot more work.

    The Story: I am repairing the family 2005 Prius that has been sitting unused for a few years. I jumped the car and it fired up and surprisingly didn't have a red triangle of death. I did some repairs to the brakes and suspension and drove it around for a few weeks before the red triangle came up. I tired to use Dr. Prius to do a battery scan but it told me the battery was too cold to test and so i decided to just remove the whole pack and try and test modules. Eventually i ended up getting battery chargers that could do charge and discharge cycles and i cycled every module until they had 4500 Ah discharge capacity or better. Those that didn't I replaced with good used cells from eBay which i tested the same. I then balanced all the cells by connecting all the positive sides together and all the negative sides together for 24hrs.

    Now i have reinstalled the pack back in the car and it looks healthy on the battery monitor on Dr. Prius, but I still have the same Warning! Battery too cold to continue the test (77F) error preventing me from doing a full battery test. The red triangle also came on when i was briefly riding on the freeway with code P3000 which i cleared with Dr. Prius hoping that it was just due to the battery's needing to cycle or charge together as a unit. It didn't come back on in the next 15 mins of the drive though i didn't drive any further.

    Can anyone help me understand what might be my issue with the cold battery thing. Its not crazy cold outside and 78-83 degrees F on the monitor seems like a range that it would be able to test at. I also noticed under a harsh braking that the pack voltage went red (271.16 Volts) due to the regenerative braking. Is that an issue? Is there supposed to be something limiting that. As soon as i eased off the brake that number when down lower...

    I also attached a PDF of the discharge/charge cycling of the batteries if that helps at all.

    upload_2025-12-9_14-0-28.png upload_2025-12-9_14-0-39.png upload_2025-12-9_14-0-58.png
     

    Attached Files:

  2. Tombukt2

    Tombukt2 Senior Member

    Joined:
    Nov 29, 2020
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    Location:
    Durham NC
    Vehicle:
    2009 Prius
    Model:
    Base
    IM no battery expert I keep about 4 cars and 5 batteries here. Wen these goings on take place and all I've got are battery codes I swap in one of my batteries . Usually car fire right up . And I carry on . 8 give the other battery to my buddy . He hands it back saying several modules blah blah . He's already run it in his car . I return it to shelf till next car .