Reassembly: unsure of torque requirements for compressing cells together after installing new cells.

Tight

 

The clamp assembly for the modules has black crossbar tubes that control how much the modules are compressed. The bolts you're talking about thread into these tubes. Just tighten the bolts until the tubes are bottomed out on the white side plates and the bolts stop turning. There's nothing to worry about. The bar length in the Gen 2 battery is exactly what's needed for 28 modules.

 

Torque values likely shown in this. Not seeing it, can dig more. The Repair Manual doesn't seem to get into breaking down the pack into individual modules, so maybe they don't mention. Odd though.

 

I guess if we really need to use a specific value. Try 22 ft-lb.
The bolt is an 8mm with 1.25 thread pitch. Type 8T. Toyota spec is 22 ft-lb per the Service Specification section of the repair manual.
Now that we know a number, we can all sleep better tonight.

 

My bottom crossbar tubes are not accepting my bolts anymore after so many times replacing modules, things start to give and wear, I may have accidentally before messed up the inner tubes of the bottom cross bars. People talk about using aluminum foil as an option to fix a thread, any suggestions would be appreciated!

 

These are metal tubes, internally threaded at the ends? “Not accepting” means the bolts go in but are just spinning when they bottom out, or they jam as you’re trying to start them?

out of my depth, but a thread chaser might fix distorted threads in the tube, if you can find compatible metric.

 

Yikes. I wonder if the tube walls are thick enough to helicoil or timesert

 

These compression bars are all over ebay, usually including all the bars, endplates and bolts for like 25-30 bucks or so.
Don't risk clamp failure by jerry rigging it. The last thing you want to see is clamp failure and then all your modules bulge like a puffer fish and the battery completely fails. If you have a local rebuild company, they may have a ton of extras laying around and would probably sell one.