I recently replaced 2 modules in the HV pack. Everything seemed fine initially, but then the battery monitor started to read abnormally. It would charge more than discharge until eventually throwing a fault at block 11, accompanied by the awful smell of burning plastic. The damage is pretty apparent in the orange harness where block 10 and 11 meet. You can also see the plastic sticking to the electrodes poking out the modules. Is this just an issue with how I reset the harness and it created a short?
You probably did not have the nut tightened properly on the bus bar. What torque are you tightening the nuts to? What does the bus bar look like that was in that location?
All of the bars are soaking in a vinegar bath now. Didn’t even think to peek at that one specifically. It didn’t stand out though, they are all pretty corroded. I suspected torque could have been the issue. I’m an extreme amateur at any kind of car maintenance and just went as tight as what seemed right. I’ve since gone out and bought a torque wrench and would reinstall the bars at 48” lbs
Well I can’t help you there. Just assume it’s one of these greasy old things pictured here. None look significantly different from the others, besides one being more blue. But I know it wasn’t that one. Anyways, does this reasonably sound like user error and that I’m good to give it another go? Also, is it worth throwing some noalox on these? Whoever was in here before, be it manufacturer or whoever left the busbars slathered in some grease. Wasnt sure if I needed to reapply anything
So you took this battery apart took these bus bars off and put them back on looking like this more or less ? Yeah they usually go in a rock tumbler or get replaced w new nuts. And I'm generally take a few years for them to get to be looking like this if ever. 8 sprayed my last two assemblies with crc battery spray . On completed connections bus bar nuts tight etc last step . Last time I looked all red looking good .
