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Hybrid Battery Reconditioning – Must Known Facts

What is a Hybrid Car Battery?

Hybrid vehicles are becoming increasingly popular due to their fuel efficiency and eco-friendliness. One crucial component in hybrid cars is the hybrid battery, which stores and delivers energy to power the electric motor. Each hybrid owner should know These batteries’ unique characteristics and maintenance requirements.

Hybrid Battery Pack

In simple terms, any hybrid battery pack comprises a series of low-voltage battery cells connected to create a larger and more powerful battery. While specific details about these cells’ design, construction, and chemistry may vary between manufacturers and models, all hybrid battery packs generally follow a similar structure 

For example, In a typical Toyota Prius, there are 128 cells with 1.2 volts each. Six cells are linked in series to create a module at 7.2 volts, and these modules are connected in series to produce a 201.6-volt battery pack.

Hybrid Vehicle Battery Lifespan

For an average hybrid vehicle owner, the key factors determining the battery pack’s lifespan, durability, and performance are the battery’s SOC (State of Charge) and its SOH (State of Health). But what do these terms mean?

State of Charge (SOC)

The technical specifics of how the battery pack maintains its charge level, also called the battery’s SOC (State of Charge), are complex. However, in simple terms, a significant portion of the battery charging happens during regenerative braking. This process kicks in when the driver releases the accelerator/ brake pedal. When this happens, the motor or generator in the drivetrain switches from providing power to acting as a generator to replenish the battery’s lost energy. The magnetic forces generated during this charging process are strong enough to apply a significant braking force to the vehicle, which is why it’s called “regenerative braking.”

State of Health (SOH)

While SOC matters in the short term, SOH is far more critical for the long-term performance of a hybrid battery. Here’s why:

In any electrical system, electricity flows from a high potential to a lower one. In this case, if two batteries are connected, and one runs down, electrical energy from the fully charged battery will flow into the depleted one. This happens due to certain laws of physics.

What makes a hybrid battery fail?

A hybrid battery pack can only function properly if all its cells and modules share charging and discharging loads equally. Since these packs contain many individual cells, any malfunction in one cell affects the performance of the cells around it. A dedicated battery control module monitors each cell separately to safeguard the vehicle’s electronics. Suppose it detects a cell or module with parameters significantly different from the others (like voltage, resistance, or temperature). In that case, it will limit the entire battery pack’s charging and discharging capability to match that of the problematic cell or module.

What causes a cell or module to stop working?

There can be various reasons why a single cell or module might stop working. In everyday situations, the most common causes include:

  • Problems that occur during the manufacturing of battery cells.
  • Differences in the way cells are made.
  • Poor electrical connections between cells or modules.
  • Extremely hot or cold temperatures in the battery.
  • Physical damage to the battery when it’s being serviced as part of routine maintenance.
  • Occasionally, mistakes are made during the servicing process, although this is less common.

Signs of a failing Hybrid Battery

Recognizing signs of a failing hybrid battery is crucial for maintaining your vehicle’s performance:

    1. Decreased Fuel Efficiency: A noticeable drop in MPG leads to more frequent refueling.
    2. Increased Engine Usage: More reliance on the internal combustion engine, especially during acceleration and uphill driving.
    3. Reduced Electric-Only Mode: Limited electric-only driving range and time.
    4. Dashboard Warning Lights: Battery-related warning lights on the dashboard.
    5. Inconsistent Acceleration: Erratic acceleration, lack of power, or surging sensation.
    6. Reduced Regenerative Braking: Less effective energy recovery during deceleration.
    7. Engine Stalling: Severe cases may lead to unexpected engine stalls.
    8. Increased Heat: Overheating of the battery due to age or cooling system issues.
    9. Unusual Noises: Strange humming, buzzing, or clicking sounds from the hybrid system.
    10. Reduced Battery Capacity: Less charge-holding capacity, resulting in shorter electric-only driving ranges.
    11. Increased Fuel Costs: Higher gasoline usage due to reliance on the internal combustion engine.
    12. Difficulty Starting: Challenges in starting the vehicle, including the need for frequent jump-starts.
    13. Warning Alarms: Audible alarms or messages indicating battery issues.

Monitoring these symptoms can help determine when it’s time to address or replace your hybrid battery.

Options for Hybrid Battery Replacement

You can opt for the best hybrid batteries if you need a hybrid battery replacement. You may choose a New hybrid battery, reconditioned, or used options, with costs ranging from $1,000 to $6,000. Though seemingly high upfront, this expense should be considered a long-term investment in your vehicle’s performance and efficiency. Your choice depends on your budget, vehicle condition, and plans. Each battery option has its advantages and considerations.

Reconditioned Hybrid Battery

A reconditioned hybrid battery pack refers to a previously used or worn-out battery that has been refurbished to restore its functionality and extend its lifespan. This reconditioning process typically involves several steps, including diagnosing and replacing defective or weak battery cells, recalibrating the battery management system, and ensuring all components are in good working condition.


Cost-Effective: Refurbished batteries are typically more affordable than brand-new ones, making them an attractive option for budget-conscious vehicle owners.

Environmental Benefits: Extending the life of a hybrid battery through reconditioning can be an environmentally friendly choice, as it reduces the need to manufacture new batteries and dispose of old ones.

Improved Performance: A well-reconditioned hybrid battery can restore the vehicle’s fuel efficiency and power, allowing it to function optimally.

Are Reconditioned Hybrid Batteries Good

The quality of a reconditioned battery can vary depending on several factors, including the expertise of the refurbisher, the condition of the original battery, and the quality of replacement components used in the refurbishment process. Generally, a well-executed recondition can result in a hybrid battery that performs effectively and extends the life of a hybrid vehicle and your peace of mind.

Here’s an overview of how hybrid car batteries are repaired or reconditioned:

  • Initial Diagnosis 
  • Battery Disassembly
  • Cell Balancing
  • Deep Discharging and Cycling 
  • Bad Cell Replacement
  • Cooling System Check
  • Reassembly and Testing
  • Resetting and Clearing Fault Codes
  • Monitoring

Quality and Commitment at Aloy Hybrid Battery

Aloy Hybrid Battery is your go-to place for top-quality hybrid batteries. Our advanced hybrid technology ensures your hybrid vehicles run at their best, giving hybrid owners peace of mind. We offer these high-performance batteries at the best price, making sure you get great value for your money.

Reasonable pricing and up to 3 year warranty make our reconditioned hybrid battery stand out. Plus, they’re designed to last for a long time. We ensure hassle-free installation and offer free installation and on-time shipping.

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