battle born battery failure

[AmpCh4mp]

I’m running three Battle Born 100Ah LiFePO4 batteries with a Victron MultiPlus II and just hit an issue after four years. when I tried starting the AC (120A DC draw), the batteries immediately shut down
It turns out the positive terminal posts on all three batteries are loose internally. applying any pressure to the post causes the power to cut in and out. My connections have always been tight and I check them twice a year. I don't see any arcing, heat damage, or melted insulation on the exterior
I’ve seen others report similar internal failures on these 100Ah units. has anyone else dealt with this?
it seems like a structural defect rather than a poor external connection

 

[Alan]

A few quick confirms before you assume the worst: check torque spec on the terminals, verify you’re not bottoming out on the post with a long bolt, and make sure the lug stack is flat with no lock washer biting weird. But if the post physically shifts and the battery drops, that’s beyond external hardware. At that point it’s warranty and RMA territory.

 

[ReneKincaid]

If all three positives are loose internally after ~4 years and there’s no heat or arcing outside, that really does sound like an internal mechanical failure or fatigue from vibration and repeated torque cycles. I’d take clear video of the cut in and out behavior, grab photos of your cabling and support strain relief, and open a Battle Born ticket with serials ASAP.

 

[83tim allen]

four years of road vibration can do some weird things to internal busbars. do you do a lot of off roading or washboard roads?
even if the terminals are tight, if the heavy 00 cables aren't strain relieved (basically zip tied or bracketed so they can't wiggle), the weight of the wire itself acts like a lever on that internal post every time you hit a bump

might be worth adding some extra support for the cables when you get the replacements