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Hi Bill,
Thanks for the compliments. We are working toward making other major components like the inverters available as remanufactured as well.
We have found that the Gen1 cells are always going to have the issue of leaking. They leak around the negative terminals as well and we have found more corrosion problems with packs that had the Toyota goop recall done than the ones that did not. With that said, given some upgrades to components, the leaking takes a long time to cause any failures and we still sell some with refurbished Gen1 cells. The Gen2 cells are much more durable as you already know. They still have some leaking around the terminals, but nothing on the scale of the Gen1. Currently, we only have a few of the Gen2 cells that have failed, so we are doing our own testing to see what happened to them. In one instance, it was an internal connection issue between the cells that caused the failure, so you could say it was a factory defect that took over 30k to occur.
This cell came from a 07 Prius that was still under warranty, but we were able to buy the pack from the dealer.
I think the heat and extreme cold have a lot to do with early failures.
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