I replaced 4 bad battery modules in my son's high voltage battery. After reinstalling battery in the car, now no battery bars showing on dash and the grid charger does not show any amps when hooked up. I have looked everything over to make sure I didn't forget to hook something up, but no luck. Does anyone have any ideas on what the problem could be? Any help would be appreciated..

 

You sure about that? That implies you have 7 good ones. That's very rare.

What were the as-removed voltages of the 11 subpacks upon removal?

Master switch off, or you really messed up the build. Did you get any of the sub packs in there backwards? Have you checked the taps?

 

Everything looked right as it was going back together. With the way the cells attach to the plate, I don't see how they could be wrong. The sticks I replaced were all 12-13 volts.

 

More than one person has flipped a pair.

"12-13V volts" didn't answer the questions.

1. What were ALL eleven voltage measurements as-removed?
2. Master switch on?

 

I didn't think it was possible to reverse a pair with the way the plate goes back on? All sticks were 15-16 volts except for the one's that I replaced.

 

I take it you didn't record the voltages since you won't give the 11 measurements.

While this likely isn't the issue, I guarantee that you missed several bad subpacks.

Let's say your high voltage was 16.10. All subpacks below 16.05 are suspect. All subpacks below 16.00 are likely bad.

IS THE MASTER SWITCH ON?

 

Yes the master switch is on. Do you happen to know the pins on the orange connector to measure across for individual cell voltages?

 

https://dl.dropboxusercontent.com/s/...or%20Check.png

 

B6-B14. 12.6v
b14-b5 40.5v
B5-b13 12.7v
B13-b4 38v
B4-b12 12.9v
B12-b11 53v
B7-b1 14.3v
B1-b8 45.1v
B8-b2 15v
B2-b9 45.4v
B9-b5 15.2v

 

The diagram is for the BACK of the plug, i.e., probing the connector while it's plugged into the BCM. If you unplugged it and flipped it around, you measured incorrectly.

Of the measurements that likely overlap with a single subpack, 12.6, 12.7, 12.9, 14.3, 15.0 and 15.2, the 4 bolded ones are 100% bad, and the other two are inconclusive.