GOAL= remove old bad 8 volt batteries and update the wiring and everything in the pack to the true 12 volt NIMH system and then install a lower pack and a upper pack of a total of 25 odyssey PC2150 group 31 batteries .... for a total of a 300 volt system ............................. We do not want to stack batteries any more then we have to , this creates hot spots, you want as much air space as you can get between and around batteries so the NIMH system has a recirculation fan and a fl through fan so this will move plenty of air , by updating to the true 12 volt system it also has besides the high volume air fans , a IOM module that monitors all heat in the pack and keeps the fans moving the air if the temp gets high , the charging algorithm seems to work alright with these batteries also .............. The biggest plus is this is to since it has all these safety features makes the whole package totally ready to update to the coming Lithium batteries ................... Stay tuned this is going to be a reality and I believe I can be one of the first to do it , or at least the first one to do it with this configuration .................... |
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 OK, lets jack the truck up using a few 6 ton jack stands and a 5 ton jack ... always like using the best in safety !!! Of course I already as per the workshop manual for the rangers following the directions in the manual, I dropped the 4 bolts holding the protection bracket for the rear main pack plug in and then unplugged the rear main pack plug , then rolled up to the drivers side and unplugged the 50 pin plug by loosening the center #10 metric bolt until it came unplugged, then rolled over to the passenger side and unplugged the small 4 prong plug there ...... I have a dolly that when rolled under the ranger ev is just about 1/4" below the pack, I then just remove the 6 long large bolts to lower the pack onto the dolly ... I then jack up the ranger ev off the pack .................................... |
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 and now we get ready to roll the pack out ... here is the pack jacked up off of the pack ... |
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 I have to remove the rear left hand wheel and angle the pack out from under the ranger as I can not jack the ranger up too high as I have a low ceiling but this has not been a problem as long as I remove the wheel ............................................. |
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 Here we have the old batteries in the box, time to take them out that is for sure ............. |
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 Started removing the old batteries and I was really amazed this ranger ev has an original mileage of only 4,200 miles on it, as you can see this pack has not only gone bad but there is two different color battery stickers on them which means some batteries have already been replaced !! Only 4,000 miles and bad batteries , not any really good things to say about these original batteries if they are only lasting 4,000 miles ................................... |
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 Here they are stacked up and ready to go to the recyclers . the original batteries it seems there must have been a problem, I am taking out 3 sets of batteries this week and 2 of the 3 trucks are under 5,000 miles on the odometer !! something went wrong ................................. |
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 alright lets get down to work, I stripped out everything cleaned up the case, removed the plastic inserts and set in the new lower pack batteries and hooked up all the high voltage cables ... |
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 Here is a view of the back of the case .......................... |
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 here is the middle of the pack ............................. |
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 here is a picture of the middle recirculation fan with a custom made case ... my dad made a custom case for the center recirculation fan and the flo-through fan since they are no longer available ... I also use the center fan for the flo-through fan it works just fine it is just a little bigger ........... this install is done with all the original NIMH wiring low voltage and IOM assy and temp sensors bought off the internet as the original ones are not available either .. this is pretty much a NIMH ranger now but with the great odyssey PC 2150 group 31 batteries , I like these because they are 205 minute run time batteries at 25 amp draw , they are a full 100AH battery .................. I flash updated the BCM from a lead acid bcm to a NIMH bcm through software. |
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 here is a front end view with the flo through fan assy ........................... |
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 OK add in the low voltage wiring , the BCM assy and the IOM and bundle up the wiring and hook it all together ........................... |
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 here it is finished up the wiring, hooked it all up and ready to add the upper hole cover, add the shims to raise the lid 1" , add a new weatherstripping (it rains in oregonand needs to be sealed) |
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 drill the hole for the wiring from the lower to the upper pack and add the pvc connector .. pull the wires through seal up the box and reverse the order of removing the pack........... and there you go .... move on to the upper pack in the next section !! |
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