Edit: crossed post.
wxmatt wrote: ↑
Mon Oct 05, 2020 10:23 pm
When I opened up the onboard charger, shards of black components were rattling around on the back (below the bottom circuit board).
Upon closer inspection… This is about the most useful piece that fell out.
That's from the Waffleplate™. The Mitsubishi iMiEV has a similar (not identical) OBC, also made by Nichicon, and it also uses a Waffleplate™:
Unfortunately, it's a custom component. People have had to X-ray it to figure out what's inside:
So unfortunately, this OBC is very likely not serviceable unless you have another OBC with a spare Waffleplate™. Or maybe you're really lucky and it's only one diode, so you could find a replacement and mount it on its own heatsink. For what it's worth, failures of the Waffleplate™ are rare (in the iMiEV OBC), so you should feel special
For the life of me, I don’t know how to get that bottom circuit board out so that I can check on the bottom side. I’ve taken out all of the screws, but it seems to be held in by something… The brass pins maybe?
Yes. You need to desolder every one of those pins. This is only practical with a proper vacuum desoldering station (a cheap on will likely do), and even then some care and/or experience is required. A lot of the time, common repairs can be performed leaving the Waffleplate™ in place. Sadly, it seems that yours may not be one of those cases.
The arrows in the below are for a different purpose, but you can see all the brass pins de-soldered:
Perhaps you can take the WafflePlate™ out of the charrger (some of the screws are sneaky, follow the numbering guide), with the PCB still attached, and post a photo of the presumably damaged Waffleplate™ from one or two sides. This should give an indication of whether this OBC can be repaired.
Edit: many of the photos and ideas for the above come from this post: Troubleshooting and repair for On-board Charger (OBC), DC-DC Converter
2012 Leaf with new battery May 2019. New to me June 2019.