Fiat 500e secondary keyfob replacement case
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New case option for DYI battery replacement of Fiat 500e non-changeable battery keyfob
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Notice: I had to put some tinfoil under the replaced battery to make the contact work
The pebble key (or "Steinschlüssel" in German) of the Fiat 500e has a non-replaceable battery. When after 2-3 years the battery runs out, Fiat wants you to buy a new one. Original price for the replacement was ~300€, but I read it's down to 80€ now.
I used a knife and other general purpose tools to grind of the material covering the battery and designed a new case that puts quite some pressure on the battery/key fob. I still had to use a tiny bit of tinfoil to make a consistent contact, because I could not remove all residue from between the battery and the circuit board.
The green plug is made from TPU, to prevent dust entering the case, the rest I printed in PLA. The hole is required to be able to push the key fob out in 2 years for the next battery. The lid/lid-holder has some chamfer to avoid support structures in the slits. Everything is designed with little tolerance, so you might have to tweak it a bit.
When inserting the key fob, pay attention to the orientation: on one side on the inside, there is a ramp to replace the removed part of the casing, and put the pressure on the battery contact. Before inserting the TPU plug, this side can easily be identified.