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Rebuild a Booster Pack

If your battery-powered booster pack for jump starting car batteries wears out, rebuild it with a new battery for much less than the cost of a new booster pack.

By the DIY experts of The Family Handyman Magazine

Save money with a simple rebuild

Using a battery-powered booster pack is the safest way to jump start a car because it eliminates the possibility of sparks and alternator damage. But the lead-acid battery inside the pack doesn’t last forever. When the battery inside your booster pack stops working, you can rebuild it yourself for a fraction of the price of a new one.

You’ll need a 6-in. Phillips or star bit, a drill and a 1/4-in.-drive socket or nut driver set. Once you open the case, remove the battery and match it up at a local auto parts or battery store. If you want to order a replacement online, measure the battery’s overall size and note the terminal style and amp-hour rating. Our replacement battery cost about $35 online.

To replace your battery, start by removing the decorative trim pieces and screws (Photo 1). Then separate the case and swap the batteries (Photo 2). Reassemble the case and charge the battery until the charge light turns green. The booster pack can now be used for jump starting a dead car battery.

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Required Tools for this Project

Have the necessary tools for this DIY project lined up before you start—you’ll save time and frustration.

    • Cordless drill
    • Socket/ratchet set
    • 4-in-1 screwdriver
    • Nut driver

You’ll also need a 6-in. Phillips or star bit for the drill.

Required Materials for this Project

Avoid last-minute shopping trips by having all your materials ready ahead of time. Here's a list.

    • Replacement booster pack battery

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