Go Back   EcoModder Forum > EcoModding > Hybrids
Register Now
 Register Now
 

Reply  Post New Thread
 
Submit Tools LinkBack Thread Tools
Old 10-22-2009, 03:47 PM   This thread is in the EcoModder Project Library | #1 (permalink)
Master EcoModder
 
orange4boy's Avatar
 
Join Date: Aug 2008
Location: Canada
Posts: 1,209

The Golden Egg - '93 Toyota Previa DX
90 day: 31.91 mpg (US)

Chewie - '03 Toyota Prius
90 day: 57 mpg (US)

The Spaceship - '00 Honda Insight
Thanks: 81
Thanked 252 Times in 144 Posts
Orange4boy's Rescue and Revival of a 2003 Prius

The Honey and I have been keeping our eyes open for a cheap, fun fuel efficient second car to use instead of the Golden Egg for Bowen Island commuting and long highway trips. We looked at the classic Insight, CRX, Metro, Civic etc. but hadn't been able to find something affordable or suitable.

So We were browsing Craigslist the other day and saw a Prius for $2500. The only major problem was it was throwing a dreaded P3120 HV Transaxle failure code. We did a bunch of research and found a couple of people who had done the swap themselves so we decided to buy it.



The listing had started higher and dropped to $1500 by the time we got to see it. It's an ex Co-operative auto network car so we feel like we rescued it from it's servitude.

Now we have to get it home. Luckily one of the benefits of membership in VEVA, The Vancouver Electric Vehicle Association, is use of the VEVA car trailer. So along with Dave, the member who sold me Robotrak, the Remote controlled Elec Trak, we will pick her up later this week.

Then the "fun" starts.

Thanks to bwilson4web for your help!

__________________


Last edited by orange4boy; 10-22-2009 at 03:54 PM..
  Reply With Quote
Alt Today
Popular topics

Other popular topics in this forum...

   
Old 10-22-2009, 03:53 PM   #2 (permalink)
Administrator
 
Daox's Avatar
 
Join Date: Dec 2007
Location: Germantown, WI
Posts: 10,090

CM400E - '81 Honda CM400E
90 day: 39.62 mpg (US)

Daox's Grey Prius - '04 Toyota Prius
Team Toyota
90 day: 38.47 mpg (US)

Daox's 04 Civic - '04 Honda Civic DX
90 day: 41.58 mpg (US)

Daox's Insight - '00 Honda Insight
90 day: 64.33 mpg (US)
Thanks: 1,611
Thanked 1,916 Times in 1,179 Posts
Nice find. What does that tranny code usually indicate? Bad transmission? So you need swap a new one in?
__________________
Current project: Heating the manual trans with engine coolant
  Reply With Quote
Old 10-22-2009, 04:02 PM   #3 (permalink)
Master EcoModder
 
orange4boy's Avatar
 
Join Date: Aug 2008
Location: Canada
Posts: 1,209

The Golden Egg - '93 Toyota Previa DX
90 day: 31.91 mpg (US)

Chewie - '03 Toyota Prius
90 day: 57 mpg (US)

The Spaceship - '00 Honda Insight
Thanks: 81
Thanked 252 Times in 144 Posts
Yeah, according to Bob Wilson, supposedly what happens is somehow windings in MG2 develop a short which leads to overheating of the tranny which leads to a downward spiral. I have the entire sheaf of service records too and I can't find an entry for transaxle fluid change. These are super important from what I have read.

Now I have to find a replacement for MG2 or the whole shebang. I found one on ebay for about $700 but I'm going to keep looking locally first.

I'm wondering if the First and second Gen can be swapped. Anyone know?

There is still and off-chance that it may be under warranty if I can prove that a previous warranty defect may have caused the failure. The records show an inverter pump failure and an ecu which were fixed under warranty so maybe...
  Reply With Quote
Old 10-22-2009, 06:28 PM   #4 (permalink)
Master EcoModder
 
Join Date: Jun 2008
Location: Earth
Posts: 4,616
Thanks: 180
Thanked 670 Times in 485 Posts
Have you tried here: http://car-part.com
  Reply With Quote
Old 10-22-2009, 06:55 PM   #5 (permalink)
Master EcoModder
 
orange4boy's Avatar
 
Join Date: Aug 2008
Location: Canada
Posts: 1,209

The Golden Egg - '93 Toyota Previa DX
90 day: 31.91 mpg (US)

Chewie - '03 Toyota Prius
90 day: 57 mpg (US)

The Spaceship - '00 Honda Insight
Thanks: 81
Thanked 252 Times in 144 Posts
Thanks James.

Found one using car-part with 19000 km in Alberta. $1200. A bit pricey but with mileage that low, could be worth it.

I did find one in Richmond for 1200 also. Will have to see if they will come down a bit. Don't know the mileage.

Also found one on Ebay for $700 with 75000 km. Shipping $120

Last edited by orange4boy; 10-22-2009 at 08:13 PM..
  Reply With Quote
Old 10-22-2009, 09:01 PM   #6 (permalink)
Engineering first
 
bwilson4web's Avatar
 
Join Date: Mar 2009
Location: Huntsville, AL
Posts: 747

14 i3-REx - '14 BMW i3-REx
Last 3: 45.67 mpg (US)

17 Prime Plus - '17 Toyota Prius Prime Plus
90 day: 58.25 mpg (US)
Thanks: 70
Thanked 153 Times in 106 Posts
This is one example of a burnt MG2:



This is one of three failed transaxle I've seen photos. One failed in Germany and was disassembled and the other was documented by Art's Automotive.

Bob Wilson
__________________
Local record
Sold:

  Reply With Quote
Old 10-23-2009, 12:22 AM   #7 (permalink)
Master EcoModder
 
orange4boy's Avatar
 
Join Date: Aug 2008
Location: Canada
Posts: 1,209

The Golden Egg - '93 Toyota Previa DX
90 day: 31.91 mpg (US)

Chewie - '03 Toyota Prius
90 day: 57 mpg (US)

The Spaceship - '00 Honda Insight
Thanks: 81
Thanked 252 Times in 144 Posts
That's some serious copper.

Have they figured out what makes them short out? Electric motors are notoriously robust, their main enemy being heat. In an oil bath I suppose debris might also pose a hazard. Is there a fluid cooler on these? Who winds them? I'm guessing it's Nippon Denso.

I need a new alias... how bout rapidfirequestionboy?

I gather MG2 failure is a pretty rare occurrence.

I found some OEM shop manuals on ebay. I guess I should get the 2003. They seem to be about $130-150 a set.
__________________


Last edited by orange4boy; 10-23-2009 at 12:33 AM..
  Reply With Quote
Old 10-23-2009, 11:53 AM   #8 (permalink)
Master EcoModder
 
Join Date: Jun 2008
Location: Earth
Posts: 4,616
Thanks: 180
Thanked 670 Times in 485 Posts
Quote:
Originally Posted by orange4boy View Post
Found one using car-part with 19000 km in Alberta. $1200. A bit pricey but with mileage that low, could be worth it.
Maybe one of us is doing something wrong? I was seeing a bunch in the $600-700 range... Or were you looking just in Canada?
  Reply With Quote
Old 10-23-2009, 01:04 PM   #9 (permalink)
Master EcoModder
 
orange4boy's Avatar
 
Join Date: Aug 2008
Location: Canada
Posts: 1,209

The Golden Egg - '93 Toyota Previa DX
90 day: 31.91 mpg (US)

Chewie - '03 Toyota Prius
90 day: 57 mpg (US)

The Spaceship - '00 Honda Insight
Thanks: 81
Thanked 252 Times in 144 Posts
That would be me. I was trying Canada first. I did another search later for Washington where I could drive to pick up and found 12 units between $700-850. Looking good. Just have to pick one and go for a drive. Probably won't happen till later next week at the soonest.
__________________

  Reply With Quote
Old 10-23-2009, 08:06 PM   #10 (permalink)
Engineering first
 
bwilson4web's Avatar
 
Join Date: Mar 2009
Location: Huntsville, AL
Posts: 747

14 i3-REx - '14 BMW i3-REx
Last 3: 45.67 mpg (US)

17 Prime Plus - '17 Toyota Prius Prime Plus
90 day: 58.25 mpg (US)
Thanks: 70
Thanked 153 Times in 106 Posts
Quote:
Originally Posted by orange4boy View Post
. . .
Have they figured out what makes them short out? . . .
That remains an open question. I found one Japanese paper about voids in the potting compound and high dV/dt leading to coronal discharges in the voids. But the problem is once the internal short starts, it pretty well wipes out the initial fault ... for folks with ordinary means.
Quote:
Originally Posted by orange4boy View Post
. . .Electric motors are notoriously robust, their main enemy being heat. In an oil bath I suppose debris might also pose a hazard.
I've seen some pretty rank oil samples and suspect two things:
  1. manufacturing debris - my 5k transaxle oil change showed a small amount of metal shavings. Leave them in for 60k miles and who knows what damage they might do.
  2. micro-dieseling - admitted a long shot, I suspect high-speeds lead to micro-dieseling and accumulation of combustion by-products in the oil. These are conductive.
Quote:
Originally Posted by orange4boy View Post
. . .Is there a fluid cooler on these? Who winds them? I'm guessing it's Nippon Denso.
No idea of who makes them but there is no fluid cooler and my temperature measurements indicate none is needed.
Quote:
Originally Posted by orange4boy View Post
. . .I found some OEM shop manuals on ebay. I guess I should get the 2003. They seem to be about $130-150 a set.
That seems to be the going rate for used manuals. I bought mine new for double that.

Bob Wilson

__________________
Local record
Sold:

  Reply With Quote
Reply  Post New Thread


Thread Tools




Powered by vBulletin® Version 3.8.7
Copyright ©2000 - 2017, vBulletin Solutions, Inc.
Content Relevant URLs by vBSEO 3.5.2
All content copyright EcoModder.com