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Old 03-23-2015, 12:03 PM   #3 (permalink)
bennelson
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Join Date: Jan 2008
Location: Oconomowoc, WI, USA
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After that, I started working on taking apart the actual battery pack.

The service plug was already removed when I got the pack.

I removed about two dozen bolts from the perimeter of the battery.
I took out four larger bolts near the lift or mounting points.
In the middle, around the service plug, are six tamper resistant screws. Once those are removed, the cover can come off.

I just had to lift on a corner, and break the stickiness of the gasket.

The cover is steel, but light enough to be lifted by one person. I set it off to the side.

The cell modules are in 3 areas, so the main connections were really just a couple of bus bars and power cables. Most of the short bus bars from one cell to the next are very hard to get at and would be removed when the whole block of cell modules is removed.

I took out all the bolts that held the first block down to the battery case, attached a chain to the hoist, then lifted the block, spun it around, and lowered it out of the way.

I essentially repeated the same thing for both the other blocks of cell modules.

Removing the Nissan LEAF cells



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