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Taycan Battery repair walk through

Bennachie

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Verrrry interesting as Arte Johnson used to say. Would have been much better without the PoA clown wittering away every 5 minutes though
 

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A video of how to repair a Taycan HV Battery pack

Great video! Thanks so much for posting!
I’ve been told by my Porsche dealer the HV battery was designed to be able to replace individual battery pouches in each module but in practice they only replace an entire module rather than opening the effected module(s) and replacing individual cells.
This makes sense since it saves time and allows them to repair/rebuild failed modules & recertify off line to be used in another vehicle battery repair.
 


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Mr.Smith

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Great video! Thanks so much for posting!
I’ve been told by my Porsche dealer the HV battery was designed to be able to replace individual battery pouches in each module but in practice they only replace an entire module rather than opening the effected module(s) and replacing individual cells.
This makes sense since it saves time and allows them to repair/rebuild failed modules & recertify off line to be used in another vehicle battery repair.
Replacing the entire battery pack is great under warranty, but not if it's out of warranty and you are paying out of pocket.

I would feel much better if they replace the entire pack
 

Gino

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Replacing the entire battery pack is great under warranty, but not if it's out of warranty and you are paying out of pocket.

I would feel much better if they replace the entire pack
I’m keeping my fingers crossed my battery will need replacement before my warranty expires in Jan/2030.
 

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Verrrry interesting as Arte Johnson used to say. Would have been much better without the PoA clown wittering away every 5 minutes though
The PCA clown wrote the script, arrange time with the dealer, hired the videographer,directed the tech to answer questions, edited the video and produced the most detailed ever video on the subject to the public.
 
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Techwizard100

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He's the PCA EV chair. I'm pretty sure he asked whether there was any residual AC voltage!
Yes, proper battery voltage shutoff and safety procedures were followed.

Great video! Thanks so much for posting!
I’ve been told by my Porsche dealer the HV battery was designed to be able to replace individual battery pouches in each module but in practice they only replace an entire module rather than opening the effected module(s) and replacing individual cells.
This makes sense since it saves time and allows them to repair/rebuild failed modules & recertify off line to be used in another vehicle battery repair.
Big thanks for positive feedback. We are all volunteers here and appreciate when others see the positives in our work.
 

Techwizard100

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Great video! Thanks so much for posting!
I’ve been told by my Porsche dealer the HV battery was designed to be able to replace individual battery pouches in each module but in practice they only replace an entire module rather than opening the effected module(s) and replacing individual cells.
This makes sense since it saves time and allows them to repair/rebuild failed modules & recertify off line to be used in another vehicle battery repair.
Correct. Opening/repairing pouches would be much more difficult!
 

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I appreciated seeing the thermal paste was easy to remove…and all the little details. It was a great video.

My take away is there is so much by hand work, without doing a ton of these I struggle to see how it would come close to matching the factory install of the pack. If I were the tech I would be stressed. Deburring/fixing malformed threaded holes… scraping thermal paste and attempting to measure it to apply back.. definitely seems less field serviceable than the marketing stated :) hahah. For having such a focus on fine tolerances and spec.. this process doesn’t seem to allow for much consistency.

It would be cool to have a follow up on materials choices from the engineers that designed it, what lessons did they learn and adjust on J1.2, aside from the cover… which is still not clear to me is better for a belly pan.
 

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I appreciated seeing the thermal paste was easy to remove…and all the little details. It was a great video.

My take away is there is so much by hand work, without doing a ton of these I struggle to see how it would come close to matching the factory install of the pack. If I were the tech I would be stressed. Deburring/fixing malformed threaded holes… scraping thermal paste and attempting to measure it to apply back.. definitely seems less field serviceable than the marketing stated :) hahah. For having such a focus on fine tolerances and spec.. this process doesn’t seem to allow for much consistency.

It would be cool to have a follow up on materials choices from the engineers that designed it, what lessons did they learn and adjust on J1.2, aside from the cover… which is still not clear to me is better for a belly pan.
You can easily see how these rebuilds of EV battery packs could be improperly done by DIYers or not properly trained & certified technicians leading to overheating or water egress damage when not properly sealed.
This video shows a reasonably high level of skill & tooling is required to do the safe replacement of modules.
I can see how EV battery module repairs/replacements will become big business for up in coming EV battery service providers.
I just hope the government regulators insure any shop that works on these batteries are as proficient as the technician in the video.
This video dissuades me from ever considering doing any work on the battery module in my Taycan. I will always leave it to well trained & well equipped EV battery shops…
Thanks & keep the videos coming. Great work!
 

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They were right about one thing, don't believe everything you see on the internet. ;)

What made me skeptical only few minutes into the video is the comment that in the PB battery all modules are in series, while in PB+ some are in parallel. In fact, all modules are in parallel in both PB and PB+, and each module contains 12 cells in a 6s2p configuration, so the result is 198s2p (see below). The PB battery has 168s2p configuration, and yes it has a lower output voltage, so the expert is wrong here. The comment about Ohm's Law made by the host was funny (Ohms law has nothing to do with connecting batteries in series or parallel), but I give him a pass, he's the host, so like any other journalist trying to sound smart by throwing loosely related terms around.

Some reference materials for those interested.

Porsche Taycan Taycan Battery repair walk through 1749532582818-ij


Porsche Taycan Taycan Battery repair walk through 1749533434168-ug

I added the thinner yellow lines above to clarity how the upper level modules 18,19, and 20 connect between module 17 and 21 on lower level.
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