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Discussion Starter · #1 ·
Hello, my cousin just passed down his 2006 Insight with CVT and a dead IMA battery to me here in Rhode Island.

I've changed the fluids and have to replace the windshield, but apart from the defunct IMA system and non-functioning A/C, it seems like a good little car. I'd like to drive it for a year to work out all the bugs, then perhaps one of my daughters will have a need for it and I can pass it on to them. It drives OK without the IMA, but I can certainly tell where an extra 30 ft/lbs of torque would help the driving experience, and if I'm to pass inspection, I'll have to have all the trouble-codes gone. I know there is the IMA bypass that would eliminate the codes, but I'd like to consider actually returning the car to its full performance.

I've been reading the forums and people's pages, and looked at the websites to identify the best options; the Cardone and Dorman remanufactured packs are cost-prohibitive, and I'd like to install a pack with NEW cells, rather than reconditioned cells, or reconditioning the existing cells. My cousin did that with the existing battery pack, which fixed the problem for a few weeks, but then other cells started going bad. At 13 years old, there's a good chance of another cell giving up the ghost, which wouldn't work well for my daughters who would be driving the car in a few years. I'm also not looking for using extra-performance battery packs; original-performance would be fine for my needs.

So, here are the options I've found; I just want to know if there are any other options I'm overlooking, especially ones up here in the Northeast?

Rebuilt packs with NEW cells: (sorry; forum won't let me post links for a first post)


Bumblebee Batteries: 1 yr warranty
  • $1595+ $195 shipping
Green Tec Auto:
  • $1695 including shipping
  • This seems to be the better option, for both price and warranty
All other options seem to want to charge the above prices for rebuilt packs with reconditioned cells.

Are there any reputable rebuilders using new cells that I am missing, especially here in the Northeast?

Any caveats about the above suppliers?

Rebuilding the pack myself using NEW cells:

I cannot seem to find a straightforward supplier of new cells that I could use to rebuild the pack myself. I'm a skilled home mechanic, having rebuilt engines, transmissions and wiring-harnesses, so the task of rebuilding a pack does not dissuade me, but the price of twenty new cells that I could find on E-Bay comes close to or exceeds the cost of the above rebuilt packs with new cells.

Is there any reputable place that sells the new properly-balanced individual cells for less than $50/cell? Any more than that, and it would be worth the money to just buy one of the above packs.

Anyway, I thought I would ask what the latest is, as many of the threads I've seen are years old, and perhaps out of date.

And here's the little guy this all concerns:

84140
 

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Discussion Starter · #2 ·
OK, just found two more options, but neither is compelling except for the ABC hybrids, which is local and I could pick up from there (though I can't find a price for a rebuild with new cells):

ABC Hybrids: Honda Insight 2000-2006 Remanufactured Hybrid Battery - 12 Months Warranty, Low Deposit Due At Checkout.

Amped Hybrid: Honda Insight Battery - 1999-2006 - Partially assembled
  • $1895 + $200 shipping, but "We have replaced the cells with brand new ones that provide 40% more power than the original pack." I don't see an option for a rebuild with standard-power cells.
 

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If you want a battery that will last, buy the longest warranty you can find. Period. It's the only thing that matters, all of the other stuff is just marketing. All of the builders get their batteries from the same place in China, it's everything else that sets us apart.

If you want quality new cells, you are going to have to pay for them. :( They are very expensive to import with the trade war on-going.

Note the nomenclature difference; the only Insight pack Greentec sells with new cells is the "8Ah" for $1795.

If you really want to DIY, we still offer DIY kits of the same matched and balanced sticks that we use to assemble our completed batteries - but it costs me(and everyone else) more than $50/stick just to get them into the United States.
 
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I've bought a few standard Hybrid Revolt packs with new cells for $1300 and they work great. May have gone up $100 since then though.
 

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Warranty matters.

You can basically purchase packs starting at about $1300.00 plus shipping for a one year warranty.
$2100.00 plus shipping gets you three year warranty.
About $2400.00 plus shipping gets you a five year warranty.
As far as I know Bumblebee’s warranty is transferable. If you plan on keeping the car and handing it down in the family the warranty is a big thing. If you drive the car for a few years and decide to sell it the warranty give the car value. If the car were in an accident and not repairable the battery could be sold to another Insighter, the battery warranty still has value.
If you decide to purchase a battery please heavily consider Bumblebee. Eli has been a member of this forum for many years and has helped with battery questions and issues when they come up. He has help support this community with much technical advice.
There are times I would rather spend my money with people who help support the Insight community. Most of the other companies listed above don’t come here and help and I don’t know about their customer support in the event you have an issue.

Scott
 

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I was under the impression the warranty is like an insurance policy. They don't use any different cells, they just cover you longer. Correct me if I'm wrong.
 

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Well, of course. However, you should ask yourself how companies are able to offer such varied warranties.

As far as I know, we are still the only company that tests and has tested every cell in every (new Honda)pack we've ever sold. Batteries from many of our competitors are still wrapped in the Chinese heat shrink when you receive them. Not that there aren't other ways to glean quality control information... Everyone has their process.......

Some are better than others.. In my not so humble opinion. :D
 

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If you are a decent mechanic, consider an LTO retrofit. Once you get the LTO packs installed, you won't have to worry about them for a LONG time.
 

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Discussion Starter · #9 ·
If you are a decent mechanic, consider an LTO retrofit. Once you get the LTO packs installed, you won't have to worry about them for a LONG time.
I looked over the long thread, and that looks like far more than I'd like to get into at this moment.

I will be contacting Eli for a factory-spec battery replacement.

-Bob
 

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I am now at the point that I have to replace my pack (again) in my Y2K. I have been holding off since the spring having disconnected the BCM and running as a conventional vehicle. However, I have NYS inspection coming up in November and the CEL light has to be out. I need a three year warranty as the vehicle is required to pass emissions for the last time in November 2024 so any problems until that need to be fixed. After that (25 years), only safety inspections are still performed and when the pack eventually goes, I will switch back to conventional mode and give up.

I was surprised to see that 6.3 Ah new packs are no longer available (my bad - misread site - I was looking at refurbished page not new). I have had an 8 Ah pack since 2015 but I never found there to be any benefit. The car behaved just like it did with 6.3 Ah. I checked the Bumblebee site and I will go with Eli as I need the three year warranty.

Of course, once that is done, I then have the wonky transmission to deal with. I have been double-clutching almost a year now. Gears 1, 2 and 4 are fine and 3rd is easy enough to engage with RPM matching but 5th is becoming more problematic. Getting harder and harder to get it to "catch" and engage. That is the next project AFTER the battery. Battery is needed for inspection. Transmission is not. Funny thing is I am amazed at how well the three cylinders are doing. I cannot accelerate like a jack rabbit but at times I have been cruising at 72 MPH on flat terrain and that is impressive to me without battery assist.
 

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Can't you just borrow a pack for inspection?
I have no idea where I would find someone with one lying around to use. It would be a great solution but of course I would have to do it every year through 2024.

I had looked around to see if it was possible to get the sticks and do the rebuild myself but that is really not an option as the sticks come from China and you really need a relationship with the manufacturer if there are defective cells. Plus there is cell balancing as well that I do not have the equipment for.

I have thought about the Arduino option but I would rather hold off on that until emissions are no longer an issue.
 

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You could always buy another Insight with a known good battery and keep swapping that around. Or maybe register it in another state that isn't so strict.
 

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If you are near to Georgia, I have a pack that was in use and kept charge for a couple weeks of driving with assist. I removed it to install LTO. The pack was fully discharged prior to putting in storage. Let me know if interested and close enough to pick up, cannot ship.
 

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If you are near to Georgia, I have a pack that was in use and kept charge for a couple weeks of driving with assist. I removed it to install LTO. The pack was fully discharged prior to putting in storage. Let me know if interested and close enough to pick up, cannot ship.
Unfortunately I am on Long Island (some people say "in" Long Island but never figured out how that would work LOL). Yes shipping is a pain. At 80 lbs., they are not trivial to move. I have already done one replacement in 2015 and that was "fun" lugging the packs around.

Or maybe register it in another state that isn't so strict.
That is actually something I may have do eventually but for another reason. While the battery is only an issue through 2024, we are a CARB state and one of only three states that do not allow aftermarket catalytic converters. All those inexpensive aftermarket assemblies (compared to genuine Honda ones) are prohibited here. Last year, I developed a crack between the 2nd cat and engine pipe. Replacement would have been about $249 with an aftermarket. But no one will ship to New York and no shop would install it either under penalty of law. So I went to an exhaust specialist and he was able to repair it with a new pipe assembly he fashioned. A real craftsman. But if I were in New Jersey or Connecticut, it would be doable IF I did not have a New York license plate.

Almost every day I am reminded what an idiot I am for living here. But I still have family and I like the beaches. I am 59 and I will be leaving at retirement so I have something of a countdown running now.
 

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Unfortunately I am on Long Island (some people say "in" Long Island but never figured out how that would work LOL). Yes shipping is a pain. At 80 lbs., they are not trivial to move. I have already done one replacement in 2015 and that was "fun" lugging the packs around.
If you could wait till mid November, I am coming up to New Hope, PA and could bring pack with me. You'd need to be willing to drive over to pick up.
 

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If you could wait till mid November, I am coming up to New Hope, PA and could bring pack with me. You'd need to be willing to drive over to pick up.
If Robert isn't interested. I may be. New Hope (pretty spot), is an hour from me. Please keep me in mind. Thanks.
 
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