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Can Hybrid Batteries Be Repaired?

Updated: Aug 23, 2023

Hybrid Repair Service Logo
Hybrid Repair Service Logo

The short answer is yes. When the warnings such as the master warning triangle, check hybrid system, ABS (anti - lock brake system) and VSC (vehicle stability control) ECB Electronically controlled brake, engine management light and check hybrid system are triggered on your Toyota or Lexus, hybrid/electric vehicle, it can be by as little as a few bad modules in the entire high voltage battery when all the others are still going strong. The best option is complete battery reconditioning. This gives an opportunity to gather data on the charge and discharge capacity of your battery. When using diagnostic equipment such as Techstream (Toyota's own diagnostic equipment) and other high-end diagnostic equipment such as snap on, autel, launch etc although this equipment can measure data in block pairs (2 modules in pairs) and identify weak blocks they are incapable of give any individual module data or give any indication of exact charge and discharge capacity of your battery modules. At Hybrid Repair Service we offer a collection recondition and return service, during which, we dismantle customer hybrid batteries test all the individual battery modules and match any replacements exactly to the rest of the battery pack to achieve long lasting repairs. We have reconditioned batteries which are still going strong after 25,000 miles and giving great miles per gallon.

In many hybrid vehicles such as Toyota Prius or Lexus GS450H each NiMH module contain 6 individual cells, these modules are connected by bus bars in series configuration. Each modules nominal voltage is 7.2 volts (6 x 1.2 volt cells) In a Toyota Prius there are a total of 28 modules so in total 168 cells, where as in the Lexus GS450H there are 40 modules so 240 cells.

At Hybrid Repair Service all replacement modules are load tested and tested for capacity to ensure they are suitable for the job. New modules are available but it is not advisable to fit single brand new modules in older high voltage batteries as they will not work so well in balance with older module/cells.

Another factor can be the oxidation of the copper bus bars, the copper links which connect the modules within the battery in series. This is not problem you are going to run in to on a brand new models, but on older models like generations 1, 2 and 3 Toyota Prius, most certainly. Over time, corrosion can inhibit the connections within the battery's ability to conduct electricity, reducing battery efficiency and in turn make for worse fuel economy and in the very worst cases could be at the very least, a contributory factor in battery warnings.

Nickel plated bus bar are available, which works well to combat corrosion and although Nickel is only 7% conductive there is a thin coating of Nickel to 99.9% pure Copper, they have been seen to improve fuel economy is some vehicles when fitted.

Nickel Plated Bus Bars fitted by Hybrid Repair Service
Nickel Plated Bus Bars

Another option is to have a brand new complete replacement wiring harness including new copper bus bars.

So in short, there are many options available when it comes to servicing or repair your high voltage battery system, to make sure you get the most life from your vehicles HV battery.

At Hybrid Repair Service every single bus bar (connection between module/cells) are changed for anti corrosion nickel plated ones, where possible even with our, top quality, low price repairs. For details of our services, Please contact Mark @ Hybrid Repair Service for more information using the contact details at the bottom of the page.

Using state of the art equipment and processes Hybrid Repair Service will recondition NiMH technology batteries, processing them to regain lost capacity. This process breaks down the dendrites (crystalline structures which forms in the inside battery modules) thus, improving battery performance and fuel economy. Please note this process is not suitable for end of life batteries.

Professional Hybrid Battery Reconditioning By Hybrid Repair Service
Professional Hybrid Battery Reconditioning By Hybrid Repair Service

Get the best from your hybrid vehicle's battery by contacting Hybrid Repair Service to arrange the reconditioning of your battery today, using state of the art equipment and with a our collection recondition and return service included in the quoted price.

Tel: 07307893333

Why not check out our customer reviews for our high voltage battery repairs, reconditioning and replacement taken from Google, and Wix review system by clicking the link below

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Aug 19, 2023
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Useful info

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