Remanufactured Hybrid Toyota Honda battery - Electron Automotive - Orange, CA 714.609.5064

Generally, how do hybrid batteries work and fail?
Every hybrid and electric vehicle battery is made of multiple batteries. Even your 12 volt battery is made of 6 smaller batteries referred to as cells.

In regular hybrids they are connected in series, one to another, positive to negative. Each time you add an additional battery in series the voltage increases. With this type of configuration high voltage can be easily achieved. However, just like older Christmas lights, if one fails the whole battery fails.

Why is “cell swapping” only a temporary fix?
When a hybrid battery fails it is usually because of one or two of the smaller batteries failed. So why not use a volt meter to find the bad ones and just replace them instead of replacing the whole thing?

Well, when one or two fail, there are always several others on the verge of failing too. Many people “cell swap” their Prius battery to get it working again, but it is almost always short lived. There are many YouTube videos claiming that they fixed their battery for $50 and it lasted them several more years.

This is a great method if you are in a pinch, but from our experience we have yet to see such good results from a “cell swap”. Using a volt meter to test hybrid batteries is a very crude method and only tells you if a battery is totally bad. It does not tell you if it will be failing soon.
Professional test equipment is required to determine the remaining life in a battery and its overall state of health.

There are no simple ways or a single test that can tell you the true health of a battery. It takes time and several instruments/machines. We test each module (aka “cell”) and the data is collected and stored. This process takes several days to complete.

At the end all of this, the data is compiled and put through an algorithm which gives us an overall state of health. We are able to see everything about each battery. With this information we are able to predict the remaining life of each battery, whether it is 1 month or 10 years. The short-life batteries are sent for recycling and the long life batteries are used to keep your car on the road at a fair and affordable price.

How dangerous are hybrid batteries?
Most hybrid batteries range from 140-280 volts which can be painful at the least. This high voltage can be very dangerous but we feel that most of what we hear and read about the danger servicing these batteries is just stigma.

Fortunately, most are equipped with safety plugs, covers over the wires and bus bars, and redundancies that force you to disable the battery before removing or opening it. Once the safety plug is removed the voltage drops to a much lower level which is much safer and workable.

In our battery remanufacturing department, we do not use safety gloves when working with our batteries. It is not because we take risks or that we are very skilled. It is because once the safety plug is removed and the battery disabled, it is not possible to get a high voltage shock. Technically, it is possible to get a shock if you know exactly where to touch, but it is not realistic and at a much lower voltage.

How long do your remanufactured batteries last?
After our testing, we are able to see virtually everything about each individual battery’s state of health. That gives us the ability to predict life expectancy and performance. We segregate our batteries into different warranty lengths based on their performance in our testing process.

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