Battery Tray - Replace/Upgrade?

Battery Tray - Replace/Upgrade?

Postby Raleigh [OP] » April 25th 2016, 12:19am

Hi, I've got a 2002 Astro AWD LS 4.3 and my battery tray is rusted out. Since i'll need to replace it, I'm a) wondering if anyone has any good recommendations for a replacement, and b) has anyone ever modified this space to capacitate a larger group battery?

If you've gotta replace, why not investigate upgrades, right?
RALEIGH, Grand Rapids, MI
-2002 Chevrolet Astro LS AWD 4.3 - April 2016-Current
-1993 Jeep Cherokee 4x4 4.0HO - 2014-2016 (Sold)
-1997 Jeep Cherokee 4x4 4.0 - 2012-2014 (Sold)
-1989 Volvo 740 Sedan 16v - Died
-1994 Volvo 850 Sedan 5cyl - Died
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Re: Battery Tray - Replace/Upgrade?

Postby Lumpy » April 25th 2016, 2:44am

Raleigh wrote:
... has anyone ever modified this space to capacitate a larger group battery?



"Capacitate" - I like that!

In my van, the master cyl and related brake stuff is what limits the battery LENGTH. The fender well is what limits the HEIGHT. I could probably DEPTHITATE it by 3/4" or so. Top terminals instead of front side terminals would make that easier. It's pretty cramped getting to the side terminals in mine.


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Re: Battery Tray - Replace/Upgrade?

Postby plymouthcranbrook » April 25th 2016, 3:10am

This winter I temporarily put the battery from my 1980 Volare into my van so that I did not have to buy a new one for it until Spring. The battery from the Volare was just a little taller that the Astro battery but even so I had to remove the fuse box and turn the battery sideways to get it in. And it was a top post battery. The negative post was jammed into the underside of the fender. Had a hell of a time removing it last week when I bought a new one for the Astro.
Unless you can lower the new tray when you put in the replacement I can't see how a bigger one could be put in.
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Re: Battery Tray - Replace/Upgrade?

Postby Raleigh [OP] » April 25th 2016, 3:16am

Haha "depthitate" - gotta add that to my vocabulary! But actually that sort of describes well what I half meant... So I see the restrictions top, left, and right - but I haven't taken it out yet, is there any give below it that can be used? There's a little room in front of it, but I haven't gone a measured batteries, so I don't know if that alone would help. Also, has anyone done a straight up relocation? If this is a huge pain in the **s then no need to deliberate, however it's a fun question. Back in my Jeep days people sometimes relocated the battery to it's own box somewhere (in-cabin, floor, etc.) in order to make room for things like on-borad air, CAI systems, etc.
RALEIGH, Grand Rapids, MI
-2002 Chevrolet Astro LS AWD 4.3 - April 2016-Current
-1993 Jeep Cherokee 4x4 4.0HO - 2014-2016 (Sold)
-1997 Jeep Cherokee 4x4 4.0 - 2012-2014 (Sold)
-1989 Volvo 740 Sedan 16v - Died
-1994 Volvo 850 Sedan 5cyl - Died
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Re: Battery Tray - Replace/Upgrade?

Postby Zebediah III » April 25th 2016, 3:43am

Stealership sells them, they were less than $40
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Re: Battery Tray - Replace/Upgrade?

Postby Corsemoto » April 25th 2016, 6:13am

OE replacement battery trays are around $100 now so I'd check salvage yards for one that isn't rusted out to clean and paint/seal.

When I removed the rusty battery tray in my van I considered cleaning and soaking in Evapo-Rust (works really well), then painting or sealing with something like POR-15 but powdercoating was actually less costly and time consuming for me since I didn't have any POR-15 on hand. I wouldn't hesitate to do it this way if powdercoating wasn't an option.

Image

I had it chemically dipped and powdercoated as it was cheap, no mess for me and quick turnaround. For a little extra protection, I sprayed the tray with several coats of Plasti Dip before reinstalling.

Image

For the battery, there really isn't much extra room for a larger battery being wedged in the corner of the fender and the PCM mounted on the side. I installed a Diehard Platinum AGM 34/78 (Odyssey AGM) that I liked the specs/quality on and have been happy with it.

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Re: Battery Tray - Replace/Upgrade?

Postby Raleigh [OP] » April 25th 2016, 4:12pm

Nice job, Corsemoto! Nice battery, too - DieHards have a really good warranty right? I think I'll take your lead and take out my tray, see how bad the rust it, and fix it up if I can. I have a friend that can powder coat smaller items like that for not too much cost. I planned on getting a bunch of small pieces all at once to have him do. Nothing like a good powder coat to keep rust away!
RALEIGH, Grand Rapids, MI
-2002 Chevrolet Astro LS AWD 4.3 - April 2016-Current
-1993 Jeep Cherokee 4x4 4.0HO - 2014-2016 (Sold)
-1997 Jeep Cherokee 4x4 4.0 - 2012-2014 (Sold)
-1989 Volvo 740 Sedan 16v - Died
-1994 Volvo 850 Sedan 5cyl - Died
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Re: Battery Tray - Replace/Upgrade?

Postby Lumpy » April 25th 2016, 4:48pm

Dorman has a replacemtnt. I'm not sure if it's plastic or metal.

I made one out of 11ga steel -

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Re: Battery Tray - Replace/Upgrade?

Postby Raleigh [OP] » April 25th 2016, 8:14pm

Nice job, Lump - looks like you shaved a lot of weight off as well, I like that idea. :thumbup:
RALEIGH, Grand Rapids, MI
-2002 Chevrolet Astro LS AWD 4.3 - April 2016-Current
-1993 Jeep Cherokee 4x4 4.0HO - 2014-2016 (Sold)
-1997 Jeep Cherokee 4x4 4.0 - 2012-2014 (Sold)
-1989 Volvo 740 Sedan 16v - Died
-1994 Volvo 850 Sedan 5cyl - Died
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Re: Battery Tray - Replace/Upgrade?

Postby Corsemoto » April 25th 2016, 8:16pm

Nice tray. From researching a replacement for my van, Dorman doesn't offer a replacement battery tray for our vans (Gen I or II) that I've seen, only a hold down bracket. :shrug:
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Re: Battery Tray - Replace/Upgrade?

Postby Leeann_93 » April 26th 2016, 1:07am

I used loctite,rust,converter, dark-tinted primer and POR15 chassis coat black on mine.

From this
image.jpeg


To this
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Re: Battery Tray - Replace/Upgrade?

Postby Raleigh [OP] » April 26th 2016, 5:00pm

Nice Leeann! That's about what mine looks like, maybe a little flakier.
RALEIGH, Grand Rapids, MI
-2002 Chevrolet Astro LS AWD 4.3 - April 2016-Current
-1993 Jeep Cherokee 4x4 4.0HO - 2014-2016 (Sold)
-1997 Jeep Cherokee 4x4 4.0 - 2012-2014 (Sold)
-1989 Volvo 740 Sedan 16v - Died
-1994 Volvo 850 Sedan 5cyl - Died
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Re: Battery Tray - Replace/Upgrade?

Postby Star Stuff » July 1st 2020, 5:18pm

Sorry for resurrecting this very old thread, but I'm pulling my rusty battery tray out right now and am having a problem. I have all the bolts removed, and the clip that holds it to the top of the computer box, yet it still seems to be attached somehow to the computer box at the bottom, but I can't see down there. How is it attached?

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Re: Battery Tray - Replace/Upgrade?

Postby Leeann_93 » July 1st 2020, 10:05pm

It's not. Pull the PCM straight up.

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Re: Battery Tray - Replace/Upgrade?

Postby AstroOafAdventurer » September 19th 2020, 12:02am

Did battery trays change around 2000?
Dorman makes a replacement for 2001 & up.
Looks different, anyone know if it'll work in a 97?
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Re: Battery Tray - Replace/Upgrade?

Postby sfeaver » September 20th 2020, 2:09pm

The computer changed, so its mounting is a bit different.
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