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22.04.2014
Portland Community College’s Automotive Service Technology Program at its Sylvania Campus (12000 S.W.
Automotive Service Technology instructor Russ Jones shows first term students the dangers of working on high voltage hybrid batteries. According to PCC Auto Service instructors, they see the need because the industry is reporting more battery wear-and-tear stemming from the original hybrids that are more than a decade old.
Through the program’s own research, PCC technicians have reconditioned batteries for two Honda Civic Hybrids, improving engine performance and fuel economy. A Toyota Prius battery pack contains many small batteries that each must be worked on during the re-conditioning process. The aim is to massage this research into its curriculum to share with students, local technicians, fellow community colleges and businesses across the Pacific Northwest and beyond.
In particular, Hawthorne technicians are using PCC tools and equipment as well as the research in the auto shop’s lab to make repairs on their customer’s vehicles to test out the developments.
PCC’s Automotive Service Technology Program wants to be a regional training center for green cars. In September of 2010, PCC received a federal grant of $200,000 from the Small Business Administration (co-administered by the Department of Education).
Josh Miller, 30, of Southeast Portland and a native of Indiana, is in his first term in the Automotive Service Technology Program, pursuing a childhood dream of working on cars. The movement of transportation and human basic needs technologies toward sustainable applications has become a global concern and opens opportunities such as this that are exciting.
There are many untapped methods and technologies that should be explored toward optimizing electric and hybrid machinery.
Many people worry that if the maintenance of hybrid car to be very costly and difficult than non-hybrid vehicles.
Congratulations Russ and Kim on the outstanding work your program is providing for the students. With perusing the internet I’ve seen Toyota Priuses with well over 200,000 miles with the original NiMH battery pack and going strong. Batteries will get nano-wire technology in the coming years that will drastically increase energy densities (more electric range!). If anyone reading this wants to drive a fuel efficient hybrid but has concerns about battery longevity, then have no fear.
James, so true, I have had so many things outlive the company I purchased them from, and the company that manufactured them.
The only problem I have with hybrids and EV’s is why should I spend 30,000 bucks to save a few hundred in gas per year, plus have to pay full coverage insurance? Enter your email address to follow PCC News and recieve notifications of new posts by email. Toyota Hybrids: Prius, Camry Hybrid, Lexus CT200h, Lexus ES300h, Lexus GS450h, Lexus HS250h, Lexus LS600h Our price includes a 1 months warranty. Please note: This was our first Altima Hybrid repair and we take less time to repair!I'm extremely happy with the work done on my 2002 TOYOTA PRIUS.
Below is the side of the battery showing the bus bar and the sensor wires the battery computer uses to measure internal resistances between modules in the pack. Below is a picture of the worst battery modules we have seen, These came out of a 2002 Prius that had been driven after the error codes were displayed.
It is also an indication of how safe the nickel metal hydrate battery design is as the surrounding cells were blackened but showed no obvious physical damage.
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When the second-generation Toyota Prius arrived back in the fall of 2003, it was met with a reception not unlike that of a stranger in a small town.
Toyota responded with a press release pointing out that the hybrid wires run through the floor hump in the middle of the car and not the doors, that the hybrid batteries are 100 percent recyclable, and that, to date, very few Priuses have required hybrid battery replacement – despite being on the road since 2000 (starting with the first-generation Prius). The Daily Mail, originators of an article charging that the making of hybrid batteries irreparably harmed the landscape, later retracted the article.
The Hummer comparison originated from a report by CWN, comparing the total energy used in developing and manufacturing a vehicle, as well as the energy used during the life of the vehicle’s operation.
So, 14 years since the original Prius went on sale in the USA, and 11 years since the second-generation Prius reached our shores, the car has won over all but its most die-hard skeptics.
That $10,000 figure for the hybrid batteries was part guesstimate and part conjecture, based on the newness of the technology at the time. To understand why, you have to know that a disproportionately high number of nerds bought the Prius when it first came out. At the dealership, the diagnosis arrives: The hybrid batteries are in need of replacement—and installation of a new hybrid battery pack is $3,000 (parts and labor). Throughout the country, there are stores that now sell and install used, replacement hybrid batteries. We went with HBR’s $1400 option, and watched as HBR’s Marcos Contreras removed the back seat, removed the floor panels, removed the old hybrid battery pack, install the “new” battery pack, put the panels and seats back in, and tested the car in less than one hour. It’s been two months since the Prius had its transplant, and there’s no sign that the car ever suffered a heart attack. Now we don’t think getting used batteries is the way to go for everyone, even if the replacement cells have less mileage.
It was, in fact, Toyota that suggested owners don’t neccessarily need to replace the entire hybrid battery pack with a new unit. With hybrid battery repair now available for the cost of a major tune-up, the last of the great hybrid myths has been laid to rest.
Service 1 : Repair of individual cells in the hybrid battery pack (90 day, 3000 mile warranty).
Service 2: Replacement of all cells with low mileage cells (12 month, 12,000 mile warranty). 49th Ave.) is developing curriculum out of hybrid and electric car battery research to create a template for industry techs on how to service them more affordably.
When trouble strikes, technicians typically just replace the battery pack, which costs the consumer roughly $2,000, rather than trouble-shooting the cause.
Kim Kittinger, Automotive Service Technology instructor, said she and her students break the battery packs down, taking out individual modules and test how strong they are. The program, which is developing a 30-credit hybrid-training certificate, has partnered with two local repair shops, Hawthorne Auto Clinic in Southeast Portland and Todd’s Import Automotive in Lake Grove, to look at how they can provide better and more affordable repair work for hybrid and electric cars. In return, the shop and its customers give feedback to PCC on how well the cars are responding to the work. The college was one of several partners on the grant, but the only auto-related partner involved.
He said the automotive repair field is changing and new technicians need those green skills. Hill, an award-winning journalist and public relations writer, has been the Communications Specialist for the Office of Public Affairs at Portland Community College since November of 1999.
This new approach may prove to be an interesting alternative and presents a much needed avenue to help create demand for technicians. Hybrid and electric cars are the future and we need technicians and engineers who know how this technology works. As long as Hyundai stays in business, that would be a great deal, especially if its battery has a good range to it for commuting. I think as electric vehicles become more main stream you will see the charging stations pop around PCC.


Because we are now more able to find the weak modules We charge an additional $40 per module for every module we replace after the first one. In the case of a 2001 to 2003 Prius each block is three modules and these code isolate the problem to two or three modules. If you look at the modules you will see that there are six cells and only one of them shows obvious damage and the modules were still putting out 6 volts.
If need to replace your Toyota Prius Hybrid Battery, don't pay $xxxx to a shop when you could do it yourself for under $500.
Along with all the accolades, the technology was accompanied by fear and loathing—fear of the unknown and loathing over all the attention it was getting. The photograph that ran with the article was taken several decades ago, and the nickel mining company has since been coveted by the Canadian government for transforming the land into an eco-friendly environment. CWN raised some eyebrows when it concluded that the total life cycle energy used for a Prius was greater than that of a Hummer. In 2008, the Environmental Protection Agency revised its testing procedures to better reflect real-world driving conditions. Whether anyone actually paid that much money for replacement batteries is a subject for urban legend investigators. These were tech-savvy people hell-bent on learning everything about the car—how to make it go farther on a tank of gas, how to stiffen its chassis to corner better, and how to get the multi-function display to accept satellite radio, to name just a few. One significant outcome of this mission is the emergence of a cottage industry dedicated to bringing down the cost of replacement hybrid batteries. While traversing upward on the notoriously grueling Grapevine, the dashboard lights up like a Christmas tree. As mentioned, you can even get step-by-step instructions online describing how to replace the hybrid batteries on your own (non-techies, don’t try this at home). Transitions from full electric, to gas-electric hybrid, and back to full electric feel as normal as before.
For those of you that plan on keeping your ten-year Prius for another ten years or more, you should definitely consider going with a new battery pack (yes, there are people who have every intention of keeping their Prius forever).
Shortly after the second-generation Prius came to market, Toyota issued a news release stating that the car would become so plentiful that owners could opt to replace bad hybrid cells with low-mileage used cells from the salvage yard.
They do that by seeing how long the power supply goes for by dropping the power down to their dead cells and then bringing them back up and maxing them out with energy. Jim Houser, co-owner of Hawthorne, said his company has had a longstanding relationship with PCC. The mission of the grant is to establish green jobs or advance the green skill set of workers in industry and make them more marketable. In some cases, regular routine maintenance of non-hybrid can be more expensive and more complicated than hybrid vehicles. As these generally lower maintenance vehicles are becoming more popular, less demand for the technician has been a fear amongst those of us in the field. Technicians should definitely test individual battery modules and attempt to revive the decayed ones before making an order for an entire new battery pack, and if some modules can’t be brought back to life, just order a few new modules and plug them into the pack.
This is a good reason to not keep driving a hybrid after the error codes have indicated a main battery failure. Also, the ridges between each cell on the side of the modules are there to create spacing between each module and the air is forced up to keep the modules cool. Fast forward ten years, and hybrid battery repair can be now had for the cost of a major tune-up. Outlandishly, the EPA claimed that it was capable of 51 miles per gallon on the highway and 60 miles per gallon around town. The report has since been discredited by both the automotive press and the environmental experts. But the EPA ratings of all vehicles were impacted, and the Agency still considers the Prius the most fuel-efficient car sold in America without an electric plug.
We can say that Toyota today will charge you approximately $2500 for a brand new hybrid battery pack, and about $500 for labor.
Contacting the nearest Toyota dealer, our call is connected to the automotive equivalent of an advise nurse.
A 2001 Toyota Prius with its hybrid lights flickering on the dashboard came upon his possession.
To this end, Joe hired trained technicians to replace hybrid battery packs at customer’s homes. Acceleration seems as good as the car was new, which is to say the Prius is its old, unsporty self. On the other hand, if you don’t plan on keeping your car that long, the used option is certainly worth considering. In California, consumers reached that conclusion early on, as sales of the Prius have eclipsed every other car in the state.
For the second year in a row, Consumer Reports has ranked the Prius as the best-value in cars, based on performance, reliability, and five-year ownership costs.
So 300,000 miles down the road and the battery wears out, they’ll recycle the old one and give you a new battery for free. Lots of people flocked to the car with open arms, and it collected a number of car-of-the-year awards along the way.
Chief among the criticisms: CNW assumed that the lifespan of the Prius is just over 100,000 miles. In the real world, however, you can get replacement hybrid batteries for a small fraction of that price. You can even find step-by-step instructions online to dismantle the hybrid battery pack and replace it with a new pack.
Amazingly, the excellent gas mileage has only improved since it was brand new, if ever so slightly. It is hard on the battery and the motor generators in the transmission.) The obvious damage shows what goes wrong with a pack. With hundreds of thousands of Prii already on California roads, Joe realized that these cars sooner or later will need hybrid battery repair—and that he can do it for less than what the dealer charges. In addition to hybrid battery replacement, the company expanded out to include the usual oil change and brake service, to hybrid inverter replacement, transmission replacement, and even engine replacement. The picture is not crooked and the battery is mounted that way to allow even air flow between the battery modules. And in the transportation community, the Prius has become the dominant taxi in America, with several having gone over 300,000 miles. The air comes in from the bottom left and the space decrease as it moves to the right helping to even out the air flow between each battery module.
We will repair or replace a defective battery that is within 50 miles of Sylmar, CA or no further than 50 miles more than from where we original replaced it.



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