Did you know every Hybrid out there ( that I know of, even the few plug ins ) are powered by D batteries?

That is correct.
The Ford Escape, having the largest pack out there has 250 "D" cell batteries wired in series. Toyotas and Hondas have the same size cells, just fewer of them in each car. The plug-in type batteries have about 1500 "D" cell batteries.

To date, we ( the industry ) are not building large batteries.
We are only building large battery arrays.

During the "recycle" process, I'll bet you a box of donuts the battery cells are discarded to the landfill, and only the metal cases, and computer components are recycled. IF a little D cell is dead, it is dead. Even if it could be "revived" somehow, I'm sure it falls under the category that it is easier and cheaper to replace with new, then to fix the old. Along the lines of the microwave oven and VCR.