One Bad Cell Killed the Range – Nissan Leaf Pack Swap to the Rescue!

Video Description

This 90,000-mile Nissan Leaf came to us with no warning lights and full drivability — but a shocking range of just 40 miles. In this video, we dive deep into high-voltage diagnostics, reveal how a single weak battery cell can cripple an EV's range, and show the full repair process — from battery removal and disassembly, to cell balancing and testing. We document: 🔍 Cell-level diagnostics 🔋 Battery pack removal & teardown 🔧 Cell replacement & voltage balancing 🧪 Real-world road tests 📊 Post-repair performance stats Can one cell bring down an entire EV battery? Yes — and here's how we fixed it. 📍 Visit Us: OGS Mechanics Units 9–14, Millers Yard Rear of 28 Long Lane London N3 2QG 📺 Watch Our Repairs in Action: 📌 Subscribe on YouTube → Weekly EV/Hybrid breakdowns, fixes & full diagnostics 📲 Follow the Behind-the-Scenes Garage Life: 🎵 TikTok: https://www.tiktok.com/@ogsmechanics 📸 Instagram: https://www.instagram.com/ogs_mechanics 📘 Facebook: https://www.facebook.com/share/15J54KFwjE/?mibextid=wwXIfr ⏱️ Timestamps: 00:00 – Nissan Leaf with poor range & no fault codes 01:12 – Diagnostic scan: One pack has major voltage imbalance 03:00 – Identifying faulty module (Pack #6) 04:27 – High voltage battery removal 05:17 – Pack teardown & visual inspection 08:30 – Voltage testing of old vs replacement cells 09:58 – Cell sandwich reassembly (critical step) 12:00 – Battery reinstallation & resealing 14:16 – First power-up and cell voltage test 17:22 – Full charge, road test, and range data 22:00 – Cell differences under load 25:00 – Final observations & handover to customer 26:34 – Repair cost (revealed) #NissanLeaf #EVRepair #BatteryReplacement #HighVoltageBattery #ElectricCarFix #LeafBatteryRepair #EVRange #OneBadCell #OGSMechanics #EVWorkshop #EVDiagnostics #EVBatteryRepair #EVGarage #NissanLeafFix #ElectricVehicleRepair Music from #InAudio: https://inaudio.org/ Track Name. Sport Trap Rock Workout by Infraction [No Copyright Music] / Are You Ready