ranger ev bad modules
Replace (3) bad modules with (2) 12 volt batteries
OK, I have 2 bad modules and a pack that only goes 12 miles to the charge I am going to show the steps I am using to get another 1,000 miles or so out of this bad pack since I am waiting for my Lifepo4 battery cells I ordered for this ranger ev ..................
 
 
 
 
 
 
 
 
 
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This is the sheet from the battery test .. it shows a very obvious reason the pack is failing ...
battery #38 the voltage shows the battery has all but completely failed ! it has a voltage of 4.43 volts while all the others are 8.20+ volts .......    this will put up a fault from being over 1 volt below the rest of the pack .....  the reason the pack shows that it only has a 12 mile per charge distance is that the pack shows bottom due to battery #5 hitting 3% when the rest of the pack is still at 40%+ so this pack should be approx. 25 miles to the charge maybe 30 on flat ground so there is not a whole lot of life left in the pack but hopefully by exchanging the lowest 3 battery modules I can get by since I only have to go 10 miles to work and I can charge there ... I can at least get by for a couple of weeks not using fossil fuels ............................
Ok I jumped right in as I dont expect this to take long ... I removed battery # 5 and # 38 from the pack ... as they are the two that are showing total failures .............
I then removed battery #'s 28, 29 and 30 as they can be removed easily and the height of the trojan group 24 batteries is just high enough they need to be in the middle of the pack to clear so I dont have to change anything else hopefully ..................
I then used 2 of these 3 batteries to replace the bad #5 and #38 .. I then split batteries #14 and 15 moved them to the extreme outsides since they are shorter then the trojans and put the trojans in the middle of the pack where the pack is taller .. I then added the resistor packs and buttoned up the wiring to them ........ this finishes the replacement of 3 8 volts with 2 12 volt trojan batteries in the pack ...
 
well now is the time of the truth or not will the ranger ev accept the 2 batteries in place of the originals .....  rolled the pack under reset all the historical data with the NGS tester cleared the memory by removing the negative cable on the aux. battery and plugged in the charger ...
it is currently charging so that is a good sign that it thinks the batteries are good now ...
I will let it charge up for a while and then I will roll it back out from under the ranger ev and put the top on and seal it all up and put it in the ranger ev for driving while I wait for my Lifepo4 cells to finally show up ..........................