How do you remove old lead-acid batteries and prepare the tray for a lithium retrofit?

Direct answer: Make the cart safe, disconnect and label the cables, lift the lead-acid batteries out with proper handling, neutralise and clean the tray, repair corrosion, then plan the hold-down, cable runs, fuse and charge port for the new pack using its published dimensions before it arrives. Send the old batteries to a lead-acid recycler or the supplier’s take-back scheme under local rules.

Make it safe. Park on a level surface, remove the key, set the run/tow switch to tow if the cart has one, and wear eye protection and acid-resistant gloves. Lead-acid batteries contain sulfuric acid and can release hydrogen when charged, so no flames or sparks near them. Follow the cart maker’s service manual for your model.

Disconnect and label. Photograph the wiring first. Disconnect the main negative, then the main positive, then the links between batteries. Label the cables that will be reused (controller, charger port, accessories) and note where any 12V accessory feed was taken from one or two batteries; after the conversion that needs a DC-DC converter, see DC-DC converters for 12V accessories.

Lift the batteries. Each lead-acid golf battery is heavy, so use a lifting strap or carrier and two people where needed, and keep them upright to avoid acid spills. Put them on a pallet in a dry area for collection.

Clean the tray. Neutralise acid residue with a baking-soda solution, rinse sparingly, and dry. Inspect the metal for corrosion, cracks or thinning around mounting points; wire-brush and paint, or repair, before the new pack goes in. Replace corroded cables and lugs rather than cleaning them.

Plan the fit. Use the pack’s published size: the 48V 100Ah lists 460 × 334 × 247 mm and 43 kg, the 48V 150Ah 510 × 410 × 235 mm and 55 kg, and the 36V 100Ah 385 × 338 × 245 mm and 34 kg. A single pack leaves gaps, so plan a bracket or hold-down that stops movement in every direction. The packs list M8 terminals; size lugs to match. Plan a main fuse, the charge-port connection and, where used, the display or app. Our post on measuring the tray before ordering covers the measurements.

Disposal. Lead-acid batteries are widely recycled, but rules for storage, transport and who may collect them differ by region. Use a licensed recycler or the battery seller’s take-back, and keep the receipt.