Pulling hybrid battery

Couldn't get it started couple of weeks ago

Yes I understand there is high voltage inside I bought PPE (Personal protective equipment ) for this 1,000 volt rated linemans gloves and the protector gloves for the linemans gloves

i think the battery pack is stuck or maybe i missed a bolt somewhere

i know it weights about 110 pounds and will take about two people to get out ..


i know the Cells are dead I just need to charge it up a bit, start it and get it running for it's engine repair


there seems to be a Wax seal or silicone on one of the bolt studs could this be keeping it from budging free?

front 2 corners there's a 18mm nut on a stud. back side has a bolt on each side. I believe 13mm? something like that. nothing else. Just pry it up to break it loose if it's never been out.


make sure the orange disconnect plug is removed. put on gloves if you don't feel comfortable. remove the black cover over the main wires. test for voltage. red to ground, black to ground and red to black. it should be zero.

at that point remove the gloves, you don't work in them so you don't damage them. remove any other connectors and the 4 mounting bolts and lift up. I've had mine out one time and apart probably 10. as long as the orange plug is out, you have no more than 16v or so anywhere inside the pack.



what are you using to charge it? you can also just pop the top off the battery and get to everything there. I removed it once to replace cells and it's a hassle. I find it eaiser to just. work on it in the truck. if I need to get to the bolts under it holding the cells in, I just lift it up and put small 4x4 under each side. it makes it a simple 1 man job to work on.


if it's just dead, and you're really going to repair the engine. you really should have a clone tech 2 or some other good scanner by now. Just charge it thru jump assist.


on a side note, if I remember right your lifter stuck. there was just a guy here that had replaced the afm lifters, left the stock cam in place. ran the plug in dongle for years without a issue. I was blown away. I didn't think anyone had been able to do that. all the stuff I've read about putting non afm lifters on afm lobs causes a missfire. but maybe the hybrid cam is different enough grind that it works? kinda wild if so. if mine ever goes, I'll be half temped to try that over installing a non hybrid cam with afm delete and hoping it runs right.

I was able to get it out using a hammer
that seal they put on there was tough

@RebelBelle rebuilt his battery back from a guy in California if memory serves. It was running good when I put my Tech-2 on it.

How've you been Brent?

swathdiver said:

@RebelBelle rebuilt his battery back from a guy in California if memory serves. It was running good when I put my Tech-2 on it.

How've you been Brent?

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doing great i have almost enough saved up to get the engine replaced got 7500$ out of the 8300 unless you guys know were i can get one of these JASPER engines for a better price?

then i'll save up for the NEW battery 3-4 months at the most to get it saved up

just doing the initial discharge were at
Cell #1 6.97V at 1030MAh
Cell #10 4.90V 990mAh

BG1988 said:

doing great i have almost enough saved up to get the engine replaced got 7500$ out of the 8300 unless you guys know were i can get one of these JASPER engines for a better price?

then i'll save up for the NEW battery 3-4 months at the most to get it saved up

Click to expand...

Glad to hear it. I'm not up to date on the latest engine prices.