Information on Replacing 36 Volt Positive Battery Cable Nut When Performing Any Procedure Requiring removal of Positive Battery Cable Nut

Vehicles produced prior to July 15, 2006 were produced with a torque prevailing (lock) nut (see [1] in illustration). Do NOT reuse this lock nut when performing any procedure that requires the removal of the positive battery cable. If the lock nut is reused, damage to the battery cable stud may occur. Replace the existing lock nut with P/N 11610091.

If the vehicle has a non-torque prevailing nut with conventional threads, the nut can be reused (see [2] in illustration).

Caution: Follow all Cautions and Notices in Hybrid Battery Service Disconnect/Connect procedure in SI when servicing 36V positive battery cable nut. The negative cable should still be disconnected when servicing the positive terminal.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

Notice: This fastener must be finger-started when placed on stud to avoid cross-threading, stripping or breaking the positive battery cable stud. If the positive battery cable stud is broken, the entire battery pack must be replaced.

The hybrid battery pack requires a new positive battery cable nut, P/N 11610091, to be installed if the original nut is a torque prevailing (lock) nut. The new nut, P/N 11610091, should be finger-started, then torqued to the correct specification (15 N·m [11 lb ft]) found in Hybrid Battery Service Disconnect/Connect or Hybrid Energy Storage Fastener Tightening Specifications in SI.