The 10 year 180k warrantee is on the battery and control units for the battery. It was 8-80 then they extended it to 10-150. Then some California attorney got a judgement on odometer readings being higher than real readings, so Honda went to 180.
Source is Insight central website.
Replacement batteries were 5k, now they rebuild them and they are around 1900.
I think the California warranty covers AT-PZEV and not SULEV. My 01 Prius is a SULEV and I don't think it's covered. Hopefully you can find something that says other wise.
I have the letter Honda sent the previous owner about the extension of the warrantee, transferrable to me. The only exception is salvage vehicles.
It has nothing to do with California or a Toyota Prius.
I read on the Insight Central Forum that the mileage had been extended to 180k for the reason previously stated.
My Insight just passed 40k miles. The ten year period starts when the car was sold. Mine was made in April of 02, I am not sure when it was sold but certainly not before May 02.
My warrantee should be good until at least May 2012.
That is just on the hybrid specific components.
Honda also reimbursed people who had to pay for their battery before the warrantee extension.
So if you know someone who paid Honda 5k for an Insight Battery they would really like you if you told them they could get their money back.
There has also been considerable improvement in Nickel Metal Hydride Batteries over the last decade.
If you think your battery pack is going bad I would contact Toyota to see if they offer and kind of consideration as far as replacement costs. You might contact Toyota directly if you have a question. I would think they would possibly follow Honda's example.
My battery pack is made up of numerous D size cells. You may find some company offering an improved pack. Some of the Insight owners have done a lot of work rejuvenating their own packs, but it is fairly complicated. Of course another pathway would be to buy one from a wreck. The problem is you need to keep the pack in a certain percentage of charge or it will go bad if totally discharged.