Working on my HV battery pack, one of the module power stud nuts got rounded a little...then a little more...and more.*** Today, I simply could not remove that nut. NOTHING worked: not WD40, not heat, not vice grips, not a hammer and small pointy things I was settling in to dismantle the nut with my dremel tool, when I had one more idea. It worked. Here's what I had to start with: NutMess1 My thought: if I could bend the copper bus bar enough to slip it off of the neighboring power stud, I could twist it...and surely loosen the nut! So, I went after it using small punch pins, etc, mostly from the back side. Here's a sequence from the front: NutMess2 ...and from the back: NutMess3 Grabbed the whole thing with vice grips and twisted. No problem! NutMess4 Yes, the plastic is slightly mangled. The copper bus bar too... but nothing a hammer and a little edge touch-up couldn't fix: NutMess5 ***Lessons learned: * Be careful with those nuts. They are soft metal, easily harmed. * Clean before reinstalling, and use the conducting grease every time... Make sure you can remove the nuts next time!
Here's the remains of one I did 4 years ago. I think I went out and bought a brand new pair of vice grips and a miniature file kit for it.
You can get a brand new bushbar from dealership. Not sure if they sell the nuts too. I prefer to get a new bushbar if it already gets some corrosion rather than cleaning it like mad.
