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Help! Removed modules, now they won’t fit in clamp...

Discussion in 'Gen 2 Prius Main Forum' started by HerbMPG, Oct 2, 2018.

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  1. HerbMPG

    HerbMPG Junior Member

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    I’ve been discharging and charging 10 days. Today, I removed the modules from the clamp to replace 22 and 24 (28 being closest to the electronics, etc). Also lining them up to connect in parallel for final balance. Also lining them up Now they won’t all fit! If I could remove the bolt that holds the end clamp, I could fit them and tighten it down. My attempts to do so have failed...
    Is this because they’re in parallel?
     
    #1 HerbMPG, Oct 2, 2018
  2. SFO

    SFO Senior Member

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    Try assembling the pack vertically, start with an end cap, finishing with an end cap, torque down the end caps, then place the HV battery horizontally onto the metal frame and secure with the two nuts at opposite ends.
     
    #2 SFO, Oct 2, 2018
    Raytheeagle and HerbMPG like this.
  3. PriusCamper

    PriusCamper Senior Member

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    @Cody26 was having a similar problem putting them back together yesterday... His was the plastic end caps being backwards. If you keep at it you'll figure it out. Unless of course you charged the modules when the were not bolted together, which can cause the metal sides of the modules to bulge out and that means you just cost yourself a lot of money.
     
    #3 PriusCamper, Oct 2, 2018
  4. HerbMPG

    HerbMPG Junior Member

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    That did it! Now I’m cycling thes two replacements and two others, and it’s balancing time! Thank you.
     
    #4 HerbMPG, Oct 2, 2018
    Skibob, Raytheeagle, PriusCamper and 1 other person like this.
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