2001 model with bad HV battery in limp mode. Diagnosed 3 bad modules. Replaced with gen 2 modules. The newer modules are about 3/4 inch longer so I made an adapter out of strip copper in a flat "S" shape so I could connect the leads. The shield on the bus bars doesn't fit so I cut it and fitted pieces on. Added some extra insulation to shield the module terminals. After the repair, the car drove really nicely for about 2500 miles. Very solid for a 16 year old car. Then we got the same bad battery codes and limp mode. Checked and several gen 1 modules were way under voltage. Managed to pick up a pair of Gen 2 batteries so a complete module swap is now underway. Will provide details in another thread.
Necessity is the mother of invention..........It's a semi-common swap,(usually all 38 at the same time tho) but don't go cheap on the plastic insulator plates. The gen 2 modules, being longer, have less gap between the terminals and the steel case. Also keep in mind that the Gen2 alignment dimples and tabs will not properly align with the steel end plates of the Gen1 clamping system. This typically causes the tabs on the sides of the outer 2 modules to be compressed/pushed into the module. (I would assume the 3 you already installed may have this damage already) Double check your alignment before you actually torque down the clamp bolts. Hope everything goes well for you.
