Always great to read of someone who's clearly competent and know what they're doing... Keep up the good work! As for MPG, it's hard to get accurate numbers until after 50 miles or so...
If you want to replace modules on your old HV pack then you should perform discharge and charge cycles on all the modules to determine and "equalize" capacity. Either do it all at once with a grid charger like the Prolong system (more money, less time), or piecemeal with hobby chargers (more time and effort, but less money). Just replacing some modules on a battery pack as a high risk of throwing more codes as modules in different condition (capacity and state of charge) will have different voltage levels under stress. Posted via the PriusChat mobile app.
