Battery pack rebuild (full)
Full pack disassembly, weak-cell swap, reseal.
When a pack has 3+ weak cells or has dropped below 70% of nameplate capacity, a full rebuild often delivers better economics than a new pack from the OEM. We disassemble down to the cell level, replace weak cells with matched new cells, re-balance the module, re-seal the pack, and re-validate the entire assembly. The rebuilt pack typically restores 90-95% of original capacity at roughly half the cost of an OEM swap.
What's included
- Complete pack disassembly
- Cell-level capacity + IR matching
- Replacement of weak cells/modules
- New BMS sense leads if needed
- Active rebalance over 24 hours
- Re-seal with new gaskets
- Post-rebuild SoH report
Why this matters
An OEM pack replacement on a Nexon EV costs ₹6-8 lakh. A pack rebuild on the same vehicle is usually ₹2-3 lakh. For cars 3+ years out of warranty, the math is decisive — assuming the rebuild is done with matched cells and proper HV-safety protocols.
How it works
- 1
Cell-level diagnostic identifies exactly which cells need replacing.
- 2
We source matched cells (same chemistry, manufacturer, capacity bin) — no mixing brands.
- 3
HV-safety disassembly in our isolation cage.
- 4
Replace cells, re-weld busbars with calibrated equipment, re-torque to OEM spec.
- 5
Module-level balancing on a multi-channel cycler.
- 6
Pack reassembly, IP67 re-seal, HV insulation-resistance test.
- 7
Road test + final report.
What to expect
Allow 3-5 days workshop time. Loaner vehicles available for ₹500/day. We document every step photographically — you receive the build log with the final invoice. 1-year warranty on the rebuild.
What we typically find
From hundreds of inspections — what makes the report.
- 3-7 cells outside healthy range, the rest in good shape
- Original busbar welds showing micro-cracks (always replaced)
- Pack-level temperature sensor drift (calibrated as part of rebuild)
- BMS firmware behind current OEM revision (updated if you opt in)
How to prepare
- Confirm vehicle is out of OEM warranty (rebuild voids most warranties)
- Decide on cell brand preference — we recommend LG Chem or CATL prismatic
- Arrange transport home from drop-off (5-day job)
Equipment we use
- HV isolation cage with interlocks
- Cell-matched sourcing partnership with verified suppliers
- Calibrated spot/laser welder for busbars
- Multi-channel battery cycler (16 channels, 50A each)
- 1000V Megger for final isolation test
Certifications
- HV-safety trained technicians (IEC 62133 procedures)
- 1-year rebuild warranty
- Signed build log delivered with vehicle
Transparent pricing breakdown
No hidden charges. This is exactly what makes up your bill.
Disassembly + diagnostic | ₹8,000 |
Replacement cells (typical 8-cell pack rebuild) Varies by chemistry; quoted before approval | ₹24,000 |
Labour (3-5 days) | ₹12,000 |
Reassembly + HV isolation re-test | ₹4,999 |
| Total | ₹48,999 |
Listed price ₹49,999 may differ from sum of line items due to package pricing. Workshop confirms before invoicing.
What customers say
“OEM wanted ₹4.5L for a new pack. Rebuild was ₹1.8L and restored 92% of original range. Photo log was a nice touch.”
“Honest engineers — they told me upfront the rebuild would buy me ~3 more years, not 'forever'. Appreciated the realism.”
FAQs
Will it match factory range?+
Usually 85-95% of factory. We're honest if it can't.
How long?+
24-48 hours on bench.
Voids OEM warranty?+
Yes — only do this if your OEM warranty has expired or been refused.
Insurance?+
Owner's responsibility — we don't accept liability for second-life cell limitations beyond our 6-month warranty.
Who needs this
EVs with severe range loss (>40%) where new pack costs 2-3× our rebuild.
What's NOT included (honestly)
- Casing replacement
- BMS PCB replacement
Related services
Ready to book battery pack rebuild (full)?
Fixed price ₹49,999 — no surprises. Or describe a different problem and we'll match the right service.