[ausev] This weekend?

[Mark Farver]

Derek Bridges wrote:

>    What we learned at the first attempt to change out the battery pack 
>was the need to do our planning in some detail. We could take a shot at 
>removing the pack on Saturday if Roy can make arrangements with his 
>  
>
I'd have to agree with Derek here.  You want to do the work somewhere 
where you are not under a time crunch so you can stop, step back, and 
rethink if things are heading in an unsafe direction.  You are welcome 
to do the work in my garage.  I think it removing the battery out from 
under the truck will be required... installing cells while under the 
truck will be backbreaking and likely unsafe.

Here is how I pictured doing it:

Lower the truck as much as possible while still retaining enough room 
for a pallet jack under the battery box.  This can be done by removing 
tires, maybe dropping springs, and supporting the frame on short 
jackstands. Jack the pallet jack enough to take the weight of the 
battery.  Unbolt the battery mounts and electrical connectors.  Now 
1300lbs lighter the truck can be lifted with the engine crane enough to 
work the battery out from under the truck.  My only worry is that there 
would not be enough space under the lowered truck to unbolt the 
battery.  The truck can be raised and the pallet jack's height 
increased, but this increases the height the truck needs to be lifted to 
clear the pack.  Without a pallet jack a strong frame of 2x4's and a 
bunch of dolly wheels should work as Derek suggested. 

Removing the bed on a Ranger is 6 bolts on the floor of the bed, and one 
electrical connector.  We can remove the bed to lighten the rear of the 
truck and make the work area more accessible.  This will require a few 
people, since the bed is awkward and we don't want to scratch it.



Mark