VitaminJ wrote:How are you doing the swaps? Are you swapping cells to the new BMS or have you been able to swap in the new BMS too without disassembling the pack?
I have done both - swapping the complete pack into someone's Leaf, then drive at 25 MPH
to the downtown Nissan Dealer and they programmed the car to accept the new battery. They charged their standard minimum service charge which is $160 for this.
- and opening op both packs and swapping cells from the new into the old pack, so that the BMS stays with the car, so as soon as the swap is done, the car drives normally.
Main drawback of the second swap is that the mounting of the module stacks is obscured by the disconnect and contactor block and all wiring is installed on the module stacks, so *everything* has to be removed from the shell in order to swap modules, you cannot easily swap just the modules. In addition, typically the old pack has the 2011/2012 wiring which is electrically incompatible to the 2013+ BMS wiring, so all the wiring must be removed from the module stacks to use the new modules with the old BMS.
And the spacers in the new half pack stack have mounting bolts every 3 modules, whereas the old stacks have them every 2, so the retaining clips on the wiring even need to shift.
And the high power wiring on the new half pack stack is connected differently, the old bus bars on the new stack will hit two bolts and so it needs to be modified to avoid wearing through and causing a short circuit.
It is all easily possible and I have done this a couple times now, but you need to be a bit creative to get a good solution.
Or pay the dealer to program the new battery to your car...
(The dealer wants to have the registered owner of the car present to avoid helping install a stolen battery, which is logical as that was the whole point of registering the battery to the car)