You can research as much as you’d like, but when it comes down to it, fixing the battery is pretty simple.
- Check the voltage of all the modules
- Load test the modules
- Identify any suspicious modules and remove them
- Order at least as many replacement cells, perhaps one or two extra
- Purchase a battery charger or two
- Make a power supply for the battery charger
- Discharge/charge cycle each module 3 times
- Balance the pack
- Put it back in your Prius.
Here’s a link to a PriusChat forum that covers it nicely: PriuisChat thread.
Purchasing things should be done ASAP, as some of the pieces can take a bit to ship, and being out of commission for as short a time as possible is ideal. Based off my experience, I think if I were totally ready to go and had everything sitting around, it’d be roughly a week minimum. Pieces that can take a bit of time:
- Battery modules
- Power supply (could be scrounged, which would be a nice way to cut the price of repair)
- Battery chargers
Everything else is pretty easily accessible, so can be purchased locally. Ebay seems to be the place to get the replacement battery modules. I just searched for “2nd generation Prius battery” and poked through the plentiful results.
I got 2 HiTec 44169 X4-80 4-Port Multi-Chemistry Charger as the chargers. They were $120 each, which sucks, but I was in more of a rush than I was broke at that time. If you’re not in a rush, everything can be done with only a single charger – it just takes a lot longer.
I also purchased an EVGA 500 watt PSU (~35$) as a power supply for the chargers. With all of this ordered and shipping, a bit of the stress of the unknown is off.