Sodium-Ion Battery Installation Guide

Step-by-Step Installation (General Guidance)

High-voltage safety first. Hybrid battery systems contain hazardous voltages. Installation should be performed by a qualified technician or an experienced DIYer following OEM service manuals, proper PPE, and lockout/tagout procedures. If you are not fully comfortable working with high-voltage systems, do not proceed.

Read this entire guide before beginning. Steps and torque values can vary by make/model/year. Always defer to your vehicle’s service manual.

Tools and Safety Equipment

  • Class 0 (or higher) high-voltage insulated gloves with leather protectors

  • Eye protection and insulated tools

  • Torque wrench capable of inch-pound settings

  • Digital multimeter rated for CAT III or better

  • Non-conductive work surface; lifting assistance or hoist as needed

1) Vehicle Power-Down and Access

  1. Park on a level surface, engage parking brake, and turn ignition OFF.

  2. Disconnect the 12V negative terminal and secure it away from the battery post.

  3. Remove the HV service plug per the OEM procedure.

    • Many vehicles require pulling the plug, rotating the handle to the locked “open” position, and removing it completely.

  4. Wait the OEM-specified discharge interval to allow internal capacitors/contactors to fully de-energize.

  5. Remove interior trim, rear seat, panels, and any metal shields to access the HV battery enclosure.

Important: De-energizing helps protect you and can reset HV system states (SOC balancing is managed by the vehicle).

Lifting note: Factory packs can weigh ~70–120 lb+ depending on application. Use team lifting or appropriate lifting equipment.

2) Battery Pack Removal

  1. Disconnect the battery ECU connectors and any ancillary harnesses.

  2. Disconnect the HV output cable from the pack per OEM instructions.

  3. Unbolt and carefully remove the entire battery enclosure. Place it on a stable, non-conductive surface.

3) Module Removal and Preparation

  1. Remove plastic covers, busbar frames, and any terminal guards.

  2. Carefully disconnect temperature sensors and harnesses; avoid pulling on wires.

  3. Remove busbars and hardware. If reusing busbars, clean contact surfaces or replace with new nickel-plated copper busbars.

  4. Unbolt and remove the original NiMH modules from the tray. Store them safely for reuse, recycling, or disposal per local regulations.

4) Sodium-Ion Module Installation

  1. Pre-check: Using a multimeter, verify each new module’s open-circuit voltage. For best results, modules should be closely matched (e.g., within ~0.05 V of each other at room temperature).

  2. Place sodium-ion modules into the original enclosure/tray in the correct orientation.

  3. Fasten modules using OEM-style hardware. Tighten module hold-down bolts to OEM spec where available. If not specified, use the guidance provided with your kit; general rule for small M6 fasteners is “snug” plus final torque to spec.

  4. Install clean busbars and torque terminal nuts to 36 in-lb (≈4.1 N·m).

    • Do not exceed 40 in-lb (≈4.5 N·m) unless your vehicle’s manual specifies otherwise.

  5. Reinstall temperature sensors, harnesses, and terminal guards. Ensure no harness is pinched and that all connectors positively lock.

5) Reinstallation and System Re-Energize

  1. Return the battery enclosure to the vehicle and bolt it securely per OEM torque specifications.

  2. Reconnect the ECU connectors and verify all harness routing/retention points.

  3. Reconnect the HV output cable per OEM procedure.

  4. Reinstall the HV service plug exactly as specified (often insert, rotate 90°, then press until a positive click is felt).

    • If the service plug is not fully seated and latched, the vehicle will not READY/start.

  5. Reconnect the 12V negative terminal. Some vehicles may sound the alarm on reconnection; be prepared to disarm.

  6. Before replacing interior trim, enter READY mode (or start procedure) and check for warning lights or DTCs.

    • If a code appears, power down safely and re-verify all connections/torques.

Once verified, reinstall seats, trim, shields, and panels in reverse order.

6) Initial Operation

  • Perform a short, gentle drive cycle while monitoring for abnormal noises, warning lights, or thermal fan behavior.

  • Over the first several drive cycles, the vehicle’s battery management system may adapt to the new pack. Driving behavior, climate, and accessory load can influence adaptation.

Additional Safety and Compliance Notes

  • Follow vehicle manufacturer procedures for high-voltage disable/enable, torque specs, and handling of orange-colored HV components.

  • Maintain clear cooling paths; ensure fans and ducts are free of debris and correctly connected.

  • Dispose of or recycle original modules per local/regional regulations. We can provide recycling guidance on request.

  • My New Battery is not affiliated with any OEM. Vehicle names are used for fitment reference only.

  • Performance, efficiency, and drivability outcomes depend on vehicle condition, ambient temperature, installation quality, and driving patterns. We avoid promising specific MPG or range outcomes.

Need Help?

  • Email: tech@mynewbattery.com

  • Phone: (435) 669-0020

  • Address: 1104 Via Monticano, Henderson, NV 89052

  • Legal entity: TWO KINGS ONE JESTER LLC

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