HV Battery Leak detection?

Pretty much yes because usually when they leak so far that I've noticed it's in the middle of the plate it seems like so when you go to take them apart the ones that have leaked are almost like glued together. And then when you knock them apart you see whatever it is it leaks out I have read where some guys have tried to re-wet the modules yep. I've just vowed not to waste much time with that there's guys all around me just had a battery swapped out today 750 runs like a champ New bus bars everything looks great.

 

Why do you say there's a leak? What are your symptoms? What codes and INF subcodes?

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?????? Can you post photos of this. I've gone thru 1000's of modules and never had any like this. I've had plenty of Gen 1s that had the sealant modification that effectively glues the ends together.

 

I will look and see if I took pictures I had these modules sitting in a plastic container under the carport for about 9 months The hybrid doctor out of fredericksburger wherever he is and Virginia there was supposed to come down and pick them up He never came or his driver never came eventually all I did was break the racks down out of their tubular frames one rack in particular which was a green bean rebuilt numbers on top of the modules in pen and everything. When I broke that particular battery module rack assembly down all the outer module slid right off each end The ones in the middle were kind of like stuck together like lapped pieces of metal can be. I had to take my rubber mallet and smack on them to get them to separate and when I did there was this dried look like residue of gorilla glue kind of not foamy but that brownish color creamy color something another holding the business together and it wasn't glue and it looked like the modules the metal part was compromised I couldn't find cracks per se but it looked like some kind of liquid or whatever had come out of there or gel or whatever these things have in them somewhere there was a post in this list about people re-wetting modules that take some drill a hole and then put a plug?

 

I had a P0AA6 that I traced to the hybrid battery. Once open I saw leakage under 4 modules and thought that was the problem. However an insulation meter check traced the isolation fault it to the main cable and I replaced it. So how do I know which module is leaking with no obvious signs other than the stain? Or do I just put it back together as is?

 

i would take it all apart and inspect them carefully. no corrosion anywhere?

 

When a module experiences electrical continuity with the metal case, it will trigger the P0AA6 code.
Sometimes this will be due to visible leakage of electrolyte and sometimes it's due to a small internal crack allowing electrolyte to make contact with the metal threaded insert on the bottom of the module.

Take a voltage measurement between each module terminal and the metal insert on the bottom. It should be effectively zero. I've had some ready a steady 5 volts. Some may start with a voltage but then drops very fast to near zero. Those are fine. If a steady voltage, that module has an internal short to the insert and is no good. ALTHOUGH, if needed, that short can be rendered moot by placing a couple small pieces of black electrical tape between the insert and the metal case to isolate it from the case. No need to put a mounting screw into that one, as all the other modules will keep it mounted just fine.

A P0AA6 can also be caused by the voltage sensor harness where corrosion in the ecu socket or on the plug that inserts into the socket, creates the problem.

 

In fact, a P0AA6 code can be set for electrical leakage many different places in the car. The INF code ought to be checked before assuming that the battery is even the right end of the car to be looking in for the problem.



Sometimes there's a bit of confusion around the word 'leak' in this context. The P0AA6 code is about an electrical leak—invisible charged particles, not some kind of leaking goop you can see,

However, at the same time, the battery modules do contain conductive goop, and sometimes that goop does leak, and if it does, it'll be an electrical leak too, because it's conductive.

So in that case, the 'leakage' really is both electrical 'leakage' and goop 'leakage'.

But there are lots of other ways to get a P0AA6 code about electrical 'leakage' without any kind of goop 'leakage' being involved.

That's what can make this extra confusing.

 

One thing I learned this spring is the 526/614 code can be triggered by corrosion in the HV battery ecu socket.

 

Any kind of corrosion around any of that orange wired business and the stuff that controls it orange plug smaller wire business If any of that has any holdups corrosion what have you can be very problematic might be quicker to make sure of all that quickly to rule it out.