What are the specs for HV under-module bolts, and bus nuts?

I updated this a bit after I reread your post. I had thought you had two damaged fasteners at the bottom of the module.

Thread and torque is the same for the module stud and the underside fastener.

48 inch pounds. If you have one that has a snapped head, I wouldn't even be concerned about it. Now that I relize it was snapped off in a bad module and your concern is finding a new one to install in a replacement module, the faster is M5 x 0.8, has an integral flat washer and is about 8mm long under the head.

Gen 1 modules had those mounting screws on each end of the module. Gen 2 started using them only on one side and it's stayed that way. Considering how the modules interlock with each other, a missing fastener would be no biggie.

The module studs are also M5 0.8 thread. Replacements are cheap at MSC dot com.

 

Spmr torque info in attached.

 

Don't go too long on these fasteners. The last thing you want is to bottom out and risk cracking the plastic surrounding the metal insert. Cracked plastic will = P0AA6 fault if electrolyte seeps into a crack and makes contact with that insert. If you need OEM, just message your mailing info to me at the number that shows up if you click on my user name. I have hundreds and would be happy to send you some.

 

Just text your mailing info to the number listed under my user name and I'll have some on the way tomorrow.

 

Padded envelope with 5 terminal nuts and 2 busbars dropped off at USPS 6am this morning. That way you have spares if needed.

 

I ran into this thread while looking for the battery balde nut size, as I'm replacing my voltage sensor and sense wires, and found a damaged nut. I see M5 x 0.8 already mentioned, but what material am I looking for in a replacement?

 

The M5x0.8 flange nut can be purchased from McMaster-Carr in stainless steel. 50 pieces per bag for less than $12.
Item # 93033A106 $11.43 for a pack of 50

 

In order to get this done ASAP, I ended up ordering these from Amazon, as it was showing to be the quickest delivery. I'm hoping the quality doesn't turn out to be terrible.

Code:

https://www.amazon.com/dp/B08TM4DJ6P

Any thoughts?

 

Same link as above


They’ve got nylon lock sleaves. Don’t think it’d matter though.

 

Just make sure you torque all the M5 nuts and screws to 48 INCH-pounds.
Not a fan of nylocks but they should stay in place as long as they're torqued correctly.
It hurt my brain trying to read the description. Reminds me of the chinese-english instructions provided back in the 70s and 80s.

 

Anything I can test myself to check their quality? I installed a couple, torqued to 48 inch-pounds, and measured 0 ohms between each nut and its respective stud. I mean I didn't expect any different, but that was the only test I could think of.

 

If they torqued down correctly without stripping the threads then you should be good to go. The important thing is that the busbar is cleanly compressed between the fastener and the base of the module terminal stud.