Trouble with getting battery pack bolted back into battery housing

Discussion in 'Gen 2 Prius Care, Maintenance and Troubleshooting' started by Banksy, Apr 4, 2020.

  1. Banksy

    Banksy Active Member

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    So I have a fully assembled battery block

    Compression bolts have been torqued down to spec

    When I try to get the metal cover bolted on after aligning the threaded studs into these four cut outs I can't get these 28 bolt holes to line up properly.

    I think maybe I bent this at some point trying to flip it around.


    The part of the block with the black metal plate is facing the computer

    What am I missing here?

    Some help would be awesome
     
    #1 Banksy, Apr 4, 2020
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  2. SFO

    SFO Senior Member

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    #2 SFO, Apr 4, 2020
    Last edited: Apr 4, 2020
  3. Banksy

    Banksy Active Member

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    Got them all in except these last few.

    Can this be bent?
     

    Attached Files:

    #3 Banksy, Apr 4, 2020
  4. Banksy

    Banksy Active Member

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    Got it

    Thanks for the help
     
    #4 Banksy, Apr 4, 2020
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  5. TMR-JWAP

    TMR-JWAP Senior Member

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    First, be sure you have the two white side clamps aligned with the modules correctly. I've seen plenty of rebuilt batteries where they weren't.

    Yes, it's possible that the base is bent, but that would usually also cause the 4 studs to not align with the side plate cutouts.

    What does the other side look like? are those hole aligned?
     
    #5 TMR-JWAP, Apr 4, 2020
  6. Banksy

    Banksy Active Member

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    Got it in.

    Can someone please confirm the bus bar nuts torque specs?

    Is it 48 in lbs or 60

    The guide I'm using says 60 however a lot of people say 48

    Which is it?
     
    #6 Banksy, Apr 4, 2020
  7. SFO

    SFO Senior Member

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    48 inch pounds, aka four (4) ft lbs.
     
    #7 SFO, Apr 4, 2020
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