replace module without removing battery?

No. All modules are attached by a machine screw which feeds up through the bottom of the case floor plate. Also, the sides of each module interlock with the modules adjacent to it. It would be far more hassle trying to do it in the car than to just remove it to work on a bench or table top.

The Prolong kit is designed to be used while the battery is installed in the car.

 

Got to pull it. That's why the wack-a-mole concept gets very old after the second or third or..... module failure. The good news is you get faster at doing it.

Also, the battery is grounded in the car so if something goes wrong that's a bad thing.

 

well, you stated one of your main concerns was (not?) killing yourself. If given an option, most people would not work on a 200v+ system while it, and they, are sitting on a metal platform. I believe fotomoto is alluding to that. The battery would be bolted to or at least touching the car body. Your butt/elbow/knees/hands/etc would also be in contact with the steel car body. Any little slip up of accidentally making contact with the wrong thing at the wrong time could result in current flow where it doesn't belong. This is opposed to removing the battery and working on a wooden table/bench and wearing a typical shoe which has plastic/rubber soles, minimizing the possibility of an inadvertent lightning strike....

 

Read up on dc voltage as well as the real balancing thread. Use rubber type gloves if you do not know what your doing. Respect the voltage. 200+ volts dc is enough to give anyone the Darwin award.
terramir

 

Oops spell check strikes again.
The re-balancing thread under 2ng gen forums