doug2060
Forum Supporter
Recently my battery pack for my XLT started getting weak. I couldn't get it to charge much more than 8.4 volts and it wouldn't last long from there. As some of you may know these batteries can be quite expensive when buying them new. I decided to rebuild mine. There are several guides for doing this out there but I found them to be hard to find. So, I decided to post what I did in hopes it may help others.
First I got a pack of 8 rechargeable batteries. For my project I chose these Duracell NiMH 2450mAH rechargeable batteries. I got mine on ebay for $13.50. These batteries like most AA rechargeables are 1.2 volts and not 1.5.
Once my batteries arrived it was time to heat my tools of choice for the project.
I then started by removing the cover on the battery pack. It was glued in two spots at one end. Just pry around the glue to crack it so you can slide the cover off. The cover will slide back just like the one on the AA battery holder pack. Once you slide it back until it stops you can push up on the bottom center of the cover to get it to slide all the way off.
Now you old batteries are exposed. I had to snip the two metal connectors at the top from the old batteries. I got as close as I could to the battery before cutting as to leave as much as possible. I then removed the old batteries and tossed them out.
This is what I had left.
The batteris will pretty much fit just like in the AA battery holder. I did have to bend the two connectors to created some resistance to hold the rows on either side in place and to make a good connection.
I then soldered each row at both ends but not in the middle.
I then used hot glue to help secure the batteries in position. This will also help prevent them from moving around if the detector is dropped etc. The hot glue will also be easy to remove in the future if necessary.
I then put the cover back on and put it on the charger. I highly recommend not using the FAST charge option and always use the OVER-NIGHT option.
I put the battery pack in my XLT after reassembling it to test and it showed 9.2 volts. After charging for a couple hours in OVER-NIGHT mode it showed 11.2 and 11.3. After testing it seems this is the maximum voltage for these batteries. Due to them being 1.2 volts each I really didn't expect that much.
I have not had time to test how well they hold up but I will be sure to edit this post soon with more details.
First I got a pack of 8 rechargeable batteries. For my project I chose these Duracell NiMH 2450mAH rechargeable batteries. I got mine on ebay for $13.50. These batteries like most AA rechargeables are 1.2 volts and not 1.5.
Once my batteries arrived it was time to heat my tools of choice for the project.
I then started by removing the cover on the battery pack. It was glued in two spots at one end. Just pry around the glue to crack it so you can slide the cover off. The cover will slide back just like the one on the AA battery holder pack. Once you slide it back until it stops you can push up on the bottom center of the cover to get it to slide all the way off.
Now you old batteries are exposed. I had to snip the two metal connectors at the top from the old batteries. I got as close as I could to the battery before cutting as to leave as much as possible. I then removed the old batteries and tossed them out.
This is what I had left.
The batteris will pretty much fit just like in the AA battery holder. I did have to bend the two connectors to created some resistance to hold the rows on either side in place and to make a good connection.
I then soldered each row at both ends but not in the middle.
I then used hot glue to help secure the batteries in position. This will also help prevent them from moving around if the detector is dropped etc. The hot glue will also be easy to remove in the future if necessary.
I then put the cover back on and put it on the charger. I highly recommend not using the FAST charge option and always use the OVER-NIGHT option.
I put the battery pack in my XLT after reassembling it to test and it showed 9.2 volts. After charging for a couple hours in OVER-NIGHT mode it showed 11.2 and 11.3. After testing it seems this is the maximum voltage for these batteries. Due to them being 1.2 volts each I really didn't expect that much.
I have not had time to test how well they hold up but I will be sure to edit this post soon with more details.
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