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Old 01-11-2013, 03:25 AM   #167 (permalink)
eq1
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Same here - it's been a while, plus I've only done it once. But having said that, it was only a matter of identifying all the attachments and attachment points and removing them carefully. Here's a link to Mike D's website, some pictures of the orange boards. There's some instructions somewhere around there, look to the left table of contents and browse around:
http://99mpg.com/blog/batterypacksexpose/howitiswired/

A couple tips I recall:
-be real careful removing the small screws that attach the contact terminals of the PTC strips to the boards; the terminals are thin and weak, just gently straighten all of them out and then pull the board away...
-there's a handful of nuts and bolts underneath grey rubber plugs on the circuit board side.
-no need to remove the sticks from the pack just to cycle them; 4 sticks have extra thermistor wires attached, so be careful if you do pull on the sticks, so as not to pull those wires out...
-I forgot to route and attach the 4 colored wires around the circuit board/to circuit board when re-installing. Don't forget, it's a pain...
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