My tahoe hybrid battery **** the bed, and I picked up a used unit and after switching the batteries, the truck wont start.
my original pack blew a cell (took out the two beside it) but the remaining 37 all read 8.2, I was planning to repair this unit, and use the replacement as a spare in the meantime.
I switched the unit out, and the truck wont turn over.
I pulled the cover off the replacement unit (its used) and all 40 cells are reading 7.5. When I test the halfs, I get 150v from each side, but no power at the main leads (with the disconnect in)
Previous owner said it worked fine when it was parked (transmission went) is there something im over looking?

edit - my 12v battery is only a few months old, and fully charged.

 

Safety plug not fully engaged.
Fuse in safety plug blown.

 

Is there any way to open it up and check? Ive got 2, and ive tried both of them multiple times, making sure they engage?

 

The safety plug installation is a 3 step process:

1. Insert
2. Rotate lever as plug engages
3. Slide lever to lock in place and close lock switch.

Failure to do step 3 is a common mistake. If the lever is not locked in place, the lock switch remains open. The car sees this and judges that the safety plug is not installed. Starting disabled.

Process on a Prius:

 

I've checked it 100 times. Checked the key (both sets of contacts ) for continuity, along with the other plug in the metal cover for the main leads. It's got to be something stupid. I'm really scratching my head on this one.

 

do you hear the HV relay click when the key is turned to the on position?

 

No it doesn't.

 

try again with the service plug
This is a Video from an actual service plug for a GM hybrid
(GMC Yukon ) I skipped it to the part for the service plug maybe a pin got bent that goes to the HV battery for the harness make sure that is connected correctly also

 

Its giving a code of P1AE7
battery energy control module hybrid battery voltage system isolation lost
{symptom 00} current DTC, TEST NOT PASSED SINCE DTC CLEARED , TEST FAILED SINCE DTC CLEAR, HISTORY DTC, TEST NOT PASSED SINCE POWER UP,
CURRENT DTC SINCE POWER UP.

 

are the pins ok on the harness? is the harness plugged in?