3rd Gen Revel - Battery Tray Upgrade

Remove the battery compartment cover to expose the battery.

Press and hold the ON/OFF button with the blue LED ring on the battery for 5 seconds to turn the battery off.

Ensure the battery is OFF. If the blue LED is illuminated in ANY WAY the battery is not off. Press and hold the button down again for a longer period of time to turn the battery off.

Ensure the van is not connected to shore power.

If you have more than one battery, you MUST turn off each battery individually!

Turn the solar disconnect knob to the "OFF" position on the control panel in the van.

Remove the screws that secure the screen to the floor and side of the battery compartment. You only need to remove the screws for the screen that are secured to the battery compartment cover.

Remove the caps on the screw covers using a pick, and then remove all the screws securing the battery compartment cover to the floor of the van.

You do not need to remove the screws along the shower wall, just the screws outlined by the red lines in the second image.

Using a #2 Phillips bit remove the inverter disconnect from the battery compartment.

Using a 15mm socket remove the nuts securing the cable lugs to the inverter disconnect. You can discard the inverter disconnect switch as it will not be reused.

Using a 13mm socket, remove nuts securing the front and rear battery hold down bolts.

The rear bolt can be a little tricky, so sometimes its helps to remove the front nut first, and slightly turn the battery to get more access.

Make sure the battery is off and you did not accidentally turn it on. If you short the battery terminals the battery will need to be sent to Lithionics for repair. This is not covered under warranty!!

Using a #2 Phillips bit remove the screws securing the breaker to the post mount. Just let the breaker hang for now.

Unplug the CAN connector harness from the battery by depressing the release tab and pulling up on the connector.

Make sure the battery is off and you did not accidentally turn it on. If you short the battery terminals the battery will need to be sent to Lithionics for repair. This is not covered under warranty!!

Using a #2 Phillips bit, remove the screws securing the metal plate cover that is over the bus bars. This cover is located above and behind the battery and the 250A breaker.

Once the cover is free, you can rotate the battery to get it out. You can discard this cover, as it will not be reused.

With the bus bar cover out of the way, you can reach behind the battery and unplug the Anderson connector.

Rotate the battery out of the compartment a bit to allow access to the deutsch connector for the regulator. Disconnect this by depressing the release tab and pulling the connector apart.

With the Anderson connector unplugged and the regulator harness unplugged, you can now remove the battery and set aside. Take care as the battery is a bit on the heavy side.

We will need to remove the battery hold down bolts. Slide the rubber washer all the way down the bolt to secure the head of the bolt from falling after its been cut.

Using and angle grinder (or comparable tool for cutting bolts) cut the bolt right above the rubber washer you placed on the bolt. Do this for both the front and rear bolt.

Once the bolts are cut, you can use a magnetic pick up tool to remove the bolt heads. You must remove the bolt heads otherwise they will roll and rattle around when driving.

Using a 3/8" nut driver remove the screws securing the Anderson connector to the rear wall of the battery compartment.

Using a 16mm socket and wrench, remove the lower nut securing the postive lug of the Anderson cable to the breaker.

Now is a good time to check the upper positive cable on the breaker. We have found these nuts to be loose, and have the wrong order of hardware. Verify to make sure the order is as follows: Lug, flat washer, lock washer, nut. If the order is not as above, remove the nut and place the hardware back on the correct order.

We will remove the negative cable for the Anderson connector in a later step.

Use a 5/16" socket to remove the breaker control wires. Cut the old breaker control wire ring terminals off. Strip approx. 3/8" of wire, and use a wire crimper to install the provided higher quality ring terminals. Heat shrink the ring terminals when done.

Reinstall the ring terminals. Take care as to not over tighten and damage the stud.

The location of the wires on the back of the breaker does not matter.

Locate the new postive cable provided in the kit. Place the lug onto the breaker in the orientation as shown. Install the lug, flat washer, lock washer, and nut in that order. Tighten the nut with a 16mm socket.

Reinstall the breaker to the support post using the hardware previously removed. If the screw holes are stripped out, simply move the location of the screw slightly and reinstall.

Remove the plastic covers on both the positive and negative bus bars.

Using a 17mm socket remove the negative cable for the Anderson connector from the negative bus bar.

Once you remove the negative cable, you can discard the Anderson connector cable. It will not be reused.

Locate the provided new negative cable from the kit. Install this cable onto the negative bus bar in the same stud location the Anderson connector negative cable was. Use a 17mm socket to tighten the nut snug.

Using a 17mm socket, remove the cable that runs from the bus bar to where the inverter disconnect used to be at the rear of the batter compartment. You can discard this cable as it will not be reused.

To clarify we are removing the positive (red) cable that ran from the inverter DISCONNECT KNOB to the bus bar. NOT the cable that runs from the knob to the INVERTER. In the next step we will be reconnecting the inverter power cable.

Using a 17mm socket remove the positive wire as shown. This is the wire that goes form the top side of the breaker, to the bus bar.

Take the cable that ran from the disconnect knob to the inverter. Coil the excess as shown in the second image.

Place the coiled inverter power cable onto the middle postion of the bus bar as shown. Note the orientation of the cable lug. this is CRITICAL as it will allow proper connection with two cables on the stud,

Place one of the provided zip ties as shown to keep the inverter power cable coiled. Cut the tail of the zip tie with a pair of flush cutters.

Now place the positive cable from the top side of the breaker onto the middle stud as shown. Note the orientation of the cable lug end. This is CRITICAL. You want the cable lug ends as shown to allow a proper connection to avoid excess heat and damage.

Install the lock washer and then the nut, and tighten until snug. You can also secure the nut for the 1st empty stud on the bus bar. (This stud needs to stay empty to allow proper clearance.)

Check all the other nuts on the bus bars to ensure they are tight.

Reinstall the positive and negative bus bar covers at this time.

In most cases, the screws that secure the battery shelf (what the battery rests on) to the rear of the compartment have either stripped or fallen out.

Now is a good time to resecure the battery shelf using some 3/8" head self drilling screws. You can reuse the screws that are stripped, just move their location over slightly.

Using a 3/16" security Allen bit remove the positive and negative cable from the battery. We will be reusing the rubber terminal covers, temp sensor, and regulator harness. You can disgard the battery terminal bolts, as new bolts are provided in the kit. You can also discard the Anderson connector as we will not be reusing it.

Make sure the battery is off and you did not accidentally turn it on. If you short the battery terminals the battery will need to be sent to Lithionics for repair. This is not covered under warranty!!

To gain more room to install the battery and tray, unscrew the regulator. You do not need to disconnect any of the wires. You can let it hang out of the way.

Push the bundle of wires towards the front of the van to allow more space to install the battery.

Take the new provided battery tray. Place it on the shelf as shown. Do not screw the battery tray in position yet.

You need to mark the position of the battery tray with the battery in the tray. If you have the tray to far towards the rear, the battery will interfere with the plastic compartment cover, and you will not be able to install the cover.

Place the battery into the tray as shown. We will roll the battery into position. Proceed to the next step.

Continue rolling the battery upright. The upper flange of the battery tray is designed to flex upwards to allow the battery to be rotated into position.

You can have a helper pry out the rear part of the battery compartment cover as shown to aide with installation of the battery.

Some patience is required rolling the battery into the mount. Just take your time, the battery will fit in the tray. The tray is designed so the upper flange can flex to allow the battery to rotate.

With the battery in position, place the plastic battery compartment cover back into position. Make sure the cover seats fully, and is not hitting the battery. Once you are satisfied with the location of the battery tray, mark the position on the shelf using a marker or tape.

You can remove the battery from the tray so we can secure the tray in the next step.

Make sure the battery is off and you did not accidentally turn it on. If you short the battery terminals the battery will need to be sent to Lithionics for repair. This is not covered under warranty!!

Before mounting the battery tray, make sure the foam is still attached to the backside of the tray as shown. This foam is there to prevent any rattle sounds from the tray against the back wall of the battery compartment

Use the 12 washer head screws provided to secure the battery tray to the shelf and rear wall of the battery compartment.

Before installing the battery, install the provided foam tape strips to the battery as shown in the first image. This is to prevent any noise from occurring from the battery and the tray.

With the tray installed you can now install the battery into the tray for final install.

We want the postive side of the battery towards the front of the van. This is opposite of how the battery was originally installed. The battery must face as shown, with the positive side of the battery towards the front of the van.

Once the battery is installed in the tray with the positive terminal on the battery facing towards to the front of the van, you can install the battery hold down bolts provided in the kit. Insert the bolts from the top down, and install the washer and nut. Tighten with a 13mm ratcheting box wrench.

It is very important the postive terminal of the battery is towards the front of the van. Other wise the provided positive cable will not be long enough and will chafe which can potentially lead to a short circuit. Don't worry about the On/Off button, you can still reach it on the battery when the battery is installed as shown.

Slide the rubber protective boot over the cable lug as shown. Place the battery temp sensor (gray cable) and the regulator power feed (small gauge red wire) onto the terminal.

Use the provided bolt and place it through the cable lug and ring terminals. The order of the hardware for the bolt should be as follows: Bolt, lock washer, flat washer, regulator power feed, temp sensor, larger battery cable lug.

Place the positive cable assembly onto the positive terminal of the battery. Tighten the bolt using a 13mm wrench or socket. Make sure the bolt is snug. Slide the protective boot over the battery terminal.

Make sure the battery is off and you did not accidentally turn it on. If you short the battery terminals the battery will need to be sent to Lithionics for repair. This is not covered under warranty!!

Slide the protective boot onto the negative cable that was previously installed. Ensure the small gauge black wire for the regulator power harness is through the protective boot as well.

Install the negative cable assembly onto the battery with the new provided bolt. Hardware order is as follows: Bolt, lock washer, flat washer, small gauge wire for the regulator power harness, and then the large cable lug for the battery cable. Tighten with a 13mm wrench or socket until snug. Slide the protective boot over the battery terminal.

Make sure the battery is off and you did not accidentally turn it on. If you short the battery terminals the battery will need to be sent to Lithionics for repair. This is not covered under warranty!!

Route the CAN connection harness previously removed over the top of the battery and connect the harness to the battery.

Plug in the regulator power harness previously disconnected.

You can now remount the regulator to the shelf using the hardware previously removed. It does not make a difference on the orientation of the regulator, but we install them so you can read the display correctly.

Install the screws and cap previously removed that secure the battery compartment cover to the floor of the van.

Drill the old mounting holes for the inverter disconnect knob with a 9/32" drill bit. Take great care as to not drill into the battery!!

Install the provided plate cover using the 5/32" rivets provided.

Once you have the plate cover installed, you can reinstall the screen using the hardware previously removed.

Press the power "ON/OFF" button to turn the battery on. The blue LED ring should illuminate.

If you have more than one battery, you will need to turn on each battery individually.

Reinstall the battery compartment cover.

Turn the solar disconnect knob to the ON position on the control panel in the van.