My new MaxPower NiMH battery sticks arrived from China today and my mechanic friend and I are scheduled to tackle the project this weekend. I realize the OEM batteries are higher quality, but at some point a lesser quality new battery replacement makes more sense than using 11-18 year old used batteries and I'm at that point. At least the board will have a guinea pig to report results.

We will be rebuilding a 2009 HVTB, one without the factory charger.

Q1: What is the correct name of the self stick gray foam Ford used to wrap the electrical connectors? Source?
Q2. For those of you who have removed your battery trays from the HVTB, what internal components of the HVTB have to be removed/loosened/moved to access the trays?

Our current plan is to leave the HVTB in the vehicle and remove the upper and lower trays to replace the sticks outside the vehicle.

Any suggestions or tips would be greatly appreciated.

 

I can't help you with the details, but it will be much easier and more comfortable working with the pack outside of the vehicle. The actual un-bolt and remove takes 5-10 minutes.

 

good luck with your build ! post some updates please