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My system to use the individual tubes to connect to the cooling plates ended up not working... The combined force of all the tubes bent at such a tight radius caused them to "push" the manifold out of position. Any tubing that was more flexible simply kinked when trying to bend at such a tight...

Got my battery pack re-assembled (getting the modules to fit back in was VERY difficult). I'll be working on implementing my modified cooling system today and doing some testing to make sure there are no leaks before it gets put the rest of the way put back together and re-installed in the car.

I was thinking it might be possible to 3D print a "reinforced" version. 3D printed parts often aren't super strong, but with enough reinforcement in the design, it might work.

It appears the part you are referring to is a wire jumper assembly...

At thing point, with the cells already swollen, I don't want to over-compress the cells and risk causing damage, so I'm only going to compress them just enough to fit back into position. I've 3D printed a bunch of clips which will be attached to the modules with some 3M VHB. The manifolds will...

It was off another FFE. The side one was missing (probably also busted when they pulled the battery), but the center one was still intact!

Just wanted to give a little update on my FFE battery repair project so far. I've got the lower battery all torn down, just need to start cleaning everything up for re-assembly, which hopefully won't be too much of a challenge (the cells are pretty swollen). Assuming I can get the modules to...

Managed to get an intact one from a wrecking yard a little over an hour from me, so no longer needed!

I accidentally broke one of the locking levers when removing the battery to repair an internal coolant leak on my 2013 FFE (the one located behind the driver's side wheel, that of course get's caked with dirt, ugh). Anyways, it looks like the Delphi (now called Aptiv) connector must be...

Pulled the pack out and got the covers off to take a look. 3 of the clips in the center sections of the coolant manifolds popped loose from too much expansion, and it also looks like one of the coolant inlets was leaking as well.

I run an EV repair shop in Portland OR, and just picked up a FREE 2013 FFE yesterday in a non running state. I was able to get the car driving again by clearing the codes with ForScan, but it did throw the dreaded P0AA6 code on one of my test drives, and after pulling the plugs, it definitely...

Ok, so I was able to clear out a bunch of messages using ForScan, and the car magically came back to life. Test drove it around a bit over the course of the day, and I did get the dreaded P0AA6 code, which then disappeared the next time I started the car. Pulled the rubber plugs on the upper...

Just picked up the car this morning! Will start digging into it today.

That picture was actually taken a couple months ago, but at this point I think I've had a total of 3 or 4 RAV4s in here so far. Of course, down at the San Diego location, there are always at least 10-15 RAV4s on site at any give time (it's kinda like the QC Charge mascot, haha). The white one...

Howdy folks! I'm planning on picking up a non-running 2013 FFE next week, and will be working on getting it fixed up to likely keep around as a "shop car". I actually own a 3rd party EV repair shop in Portland OR (a "franchise" location for QC Charge). Not totally sure what is actually wrong...

Curious to know if there have been any updates on this project? I've been reading through the forum, and it looks like you've got quite a bit of experience with the CHAdeMO mod you installed on your Focus. I'm going to be picking up a 2013 FFE next week which is a non-runner. Plan on fixing it...