Wow. I've never seen anything like that. When cells vent/leak, they look like an alkaline battery that was drained too low and left in a device. That just looks like corrosion.

What about the rest of the case?

 

Dry no stains of water. Like I said I was able to start the car and drive but just neeeded to clear the code every time

 

So the source is either pervasive venting, which seems very unlikely, or moisture intrusion from the cooling system. Do the fans or inlet ducts show any sign of contamination beyond fine dust?

 

clean and dry

 

That's actually pretty filthy, but it doesn't look like it's moisture related.

A battery should never be exposed to any significant dust. The filter at the inlet should block it, and when the A/C is active, air is simply recirculated within the case.

This leads me to believe it may be more likely to be venting of the cells, which would have been quite catastrophic to be as pervasive as it appears.

Bummer. I was trying to talk myself into some way of using those sticks.

 

Unfortunately ! Nothing to do with the battery with the high deviation ?

 

My concern with that pack is its likely exposure to extreme temperatures. If you could measure the 50 sticks and identify the outliers (nothing outside of a 0.04V range), I would consider using a limited number of P0AA6 sticks after removing the shrink, cleaning the cells/contacts, measuring individual cell voltages, and then re-shrinking them, to try to repair the high deviation pack. I don't like it, but you have it already in hand.

 

Ok thank you Sir. I will try that. Last time I put a fan on the battery overnight, when I did the bcm self test, the del-mod-dev went to 2.19 to 1.9. I don't know if the fans helped

 

Since time has passed, the modules that will still hold a charge have decreased in voltage more than the sticks that have failed cells.

Example (numbers for illustration only):

Good stick: 6.67V (5 good cells @ 1.33V)
Bad stick: 6.33V (4 good cells @ 1.33V, 1 bad at 1.0V)

0.34V delta.

All good cells drop to 1.25V, bad cell stays at 1.0V:

Good stick: 6.25V
Bad stick: 6.00V

0.25V delta

Delta has decreased by 0.09V due to the normal behavior of good AND bad cells.

 

Ok thank you. I will update the post when I get a solution