[HOW TO] Replace iBBU 08 cell

[thatoneuser]

My LSI iBBU 08 cell was expanding/bulging, so I decided to take it apart and maybe I'll replace the cell myself instead of buying a new BBU which can cost $70 or up.
Same procedure should apply to iBBU 09 as well, since the only difference between the two is one uses lithium ion and one uses lithium polymer cell.

DISCLAIMER: WHAT YOU ARE ABOUT TO SEE IS HOW TO TAKE THE BBU APART. IN DOING SO, IT WILL VOID YOU WARRANTY (well, if you're reading this, chances are you are out of warranty anyway) AND POTENTIALLY DAMAGE THE BATTERY CELL, WHICH MAY CAUSE FIRE OR EXPLOSION. PROCEED AT YOUR OWN RISK. I AM NOT RESPONSIBLE FOR ANY DAMAGE YOU DO TO YOUR BATTERY, CONTROLLER, YOURSELF, YOUR PROPERTY, YOUR DATA, AND/OR ANYTHING ELSE.

Make sure you buy the exact same model battery cell as the label indicates on the BBU.

Step 1. Remove the clear plastic cover on the bottom of the BBU.

Step 2. Use a pair of pliers, hold tight on the three screw posts/standoffs and loosen the screws on the BBU label side. You need to hold it real tight because the end of the screw has adhesive when screwed into the standoff.

Step 3. After removing the three posts, now's the fun prying part. Use a plastic spudger and pry the circuit board away from the black plastic top cover. There is an oval shaped adhesive tape that is holding the bottom of the battery cell and the black plastic top cover.

Step 4. Once the black plastic top cover is removed, proceed with removing the battery cell from the circuit board. Again, use a plastic spudger to go underneath the cell packs and slowly but surely pry the battery cell pack away from the circuit board. Be very careful, as you may puncture the pack with whatever tool you use.

Step 5. When you pry the battery cell pack away from the circuit board, remove the yellow kapton tapes. There are two pieces protecting the connections between the battery cell pack and the circuit board to prevent short-circuiting. There is another piece that is holding the thermal couple in place. Do not lose the thermal couple (it's soldered on to the circuit board).

Step 6. The battery cell pack connectors are spot welded to the connector on the circuit board. You may cut the tabs off, or however you properly remove spot welds.

Step 7. Replace the battery cell pack. Make DOUBLE, TRIPLE, QUADRUPLE sure that your polarity is correct!! You can solder on the battery tabs to the leftover metal tabs on the circuit board. You might need to sand down the metal tabs a bit with a piece of sand paper first for the solder to work. When soldering, do not hold the iron to the pack for too long. Excessive heat is dangerous near batteries.

Step 8. Replace the thermal couple and tape it back on. Also, shield off the battery cell pack tab connections with some kapton tape or electric tape.

Step 9. You get the idea, just reverse what you have done before. You can use double sided tape to replace the adhesive that was originally in it. Replace the standoffs and the plastic cover. You may use another piece of plastic to shield off the bottom of the BBU (the circuit board side).

Step 10. Moment of truth. Plug the BBU back onto the controller and let it charge. If everything goes well, you should have a working BBU again, and by doing so you just saved yourself $50 or more (the cell is selling for around $15 on ebay).

AGAIN, THIS IS GOING TO VOID YOUR WARRANTY AND IS DANGEROUS IF YOU DON'T KNOW WHAT YOU ARE DOING. DO NOT TRY IT IF YOU DON'T KNOW HOW TO USE A SOLDERING IRON OR NOT COMFORTABLE PLAYING WITH LITHIUM BATTERY PACKS. IMPROPER HANDLING OF LITHIUM BATTERIES IS DANGEROUS AND POTENTIALLY LETHAL.