Sodium-Ion Battery Installation Guide

Step-by-Step Installation (General Instructions)

Please follow all safety precautions. This system involves high-voltage components and should only be handled by those with experience or under professional supervision. If you do not feel comfortable replacing your battery, then this guide is not for you. 

Disassembly & Battery Removal 

  1. Remove all panels and trays surrounding the battery.

  2. Unplug the 12V battery and orange HV service plug FIRST.

    This step protects your safety and helps reset error codes and normalize the state of charge (SOC) to 60%.

  3. Remove the back seat and interior trim panels. Then remove all metal shields or covers that protect the battery pack.

  4. Disconnect the ECU connectors and the orange battery power cable.

  5. Carefully remove the entire battery container and place it on a stable, non-conductive surface.

    ⚠️ Warning: The factory battery weighs between 70–120lbs (depending on what battery vehicle you have. The larger the pack the heavier. Team lifting is highly suggested. 

Module Removal & Preparation

  1. Remove the plastic covers by gently working unhooking them from the orange busbar and wire frame. Remove the copper bus bars by unbolting the 8mm bolts. Remove any temperature sensor wires from the pack and ensure they do not break. 

  2. Unbolt and remove the original NiMH modules from the bottom of the pack. 8mm bolts fasten them to the chassis tray. 

  3. Store the old modules safely if you plan to recycle or reuse them.

Sodium-Ion Module Installation

  1.  Your new sodium-ion modules should be ready to install out of the box.
    However, it’s a good idea to do a quick voltage check with a multimeter to ensure they’re balanced (no more than 0.05V difference between modules).

  2. Install the sodium-ion modules into the original battery container using the 8mm bolts to install onto the chassis. **⚠️ Snug tight is just right**

  3. Install clean copper or new nickel plated copper busbars onto the modules and torque the 8mm nuts to 36 inch pounds. **⚠️ Do not exceed 40 inch pounds.**

Reassembly & Final Checks

  1.  Place the battery pack back into the vehicle and bolt it securely in place.

  2. Reconnect the orange power cable and the ECU connectors.

  3. Plug the orange service plug back in — make sure to rotate the handle 90 degrees and then push it in until it clicks into place. ** ⚠️ Warning - if the safety plug is NOT fully inserted vehicle will not start. **

  4. Reconnect the 12V battery. **⚠️ Note: The car alarm may go off when power is restored. Be prepared to disarm it.**

  5. Before reinstalling interior trim, test start the vehicle to check for error codes.

  6. Once verified, reassemble all removed panels and components in the reverse order.

You're Done! Take a moment to celebrate!

Take it easy for the first 100 miles to let the system adapt.
Then enjoy the perks:

  • Better fuel economy

  • Increased EV driving range

  • Stronger, smoother acceleration

Welcome to the sodium-ion revolution.