What is inside the Mahindra XUV400 EL battery pack
The Mahindra XUV400 EL carries a 39.4 kWh pack built from LFP Prismatic (LiFePO4) cells arranged in 14 serviceable modules at a nominal 350 V. Pack mass lands near 292 kg including the enclosure, cooling plate, contactors and BMS harness.
Because the cells are LFP Prismatic, the recoverable value profile is dominated by lithium, copper and aluminium rather than nickel and cobalt. That decides whether a retired pack is worth repurposing, refining, or both.
| Parameter | Value |
|---|---|
| Chemistry | LFP Prismatic (LiFePO4) |
| Cell format | Prismatic hard case |
| Energy / voltage | 39.4 kWh · 350 V |
| Modules | 14 |
| Estimated pack mass | 292 kg |
| On sale since | 2023 (India) |
Step 1 — Removing and shipping a passenger pack
Packs are dropped on a vehicle lift using the OEM procedure and a rated battery table, then isolated at the service disconnect. Retired packs are UN 3480 or UN 3481 dangerous goods, so the pack must be below 30% state of charge and any deformation, swelling or thermal history declared before pickup.
One pack per UN-rated pallet box, strapped and restrained, with terminals capped and coolant ports sealed. Dealer and workshop returns are consolidated into full truckloads, typically eight or more packs per run.
- Pull the service disconnect and record pack voltage
- Drain or cap coolant lines before lifting
- Photograph the pack casing and any impact damage
- Keep the VIN and pack serial together on the manifest
Step 2 — Module-level state of health grading
Each of the 14 modules is tested independently — a whole-pack SOH figure hides the spread that decides second-life eligibility. We run a full capacity cycle, DC internal resistance measurement and impedance spectroscopy.
Our degradation model for the Mahindra XUV400 EL shows how value falls with age. Measured results replace these estimates once the pack is on the bench.
| Service year | Modelled SOH | Grade | Residual value |
|---|---|---|---|
| Year 2 | 96.6% | A — BESS ready | USD 2,075 |
| Year 4 | 93.5% | A — BESS ready | USD 2,010 |
| Year 6 | 90.4% | A — BESS ready | USD 1,945 |
| Year 8 | 87.3% | A — BESS ready | USD 1,880 |
| Year 10 | 84.2% | B — Second life | USD 1,635 |
Step 3 — What you actually recover
For modules routed to refining, a pack of this size and chemistry typically yields about 6.6 kg lithium, 0.0 kg nickel, 0.0 kg cobalt and 19.9 kg copper.
At 80% SOH our model sends about 56% of the pack to second life, worth USD 1,016, and credits USD 246 for the remainder as black mass. Avoided emissions come to roughly 1,762 kg CO2.
Field note
Step 4 — Where to send it and what paperwork you get
Mahindra XUV400 EL packs are received directly at 8 intake sites in its markets, including Chakan, Maharashtra, Sanand, Gujarat, Taloja, Maharashtra, Narela, Delhi. From there, modules move to the nearest grading bench and refinery.
Every consignment closes with a certificate showing quantity processed, recovery percentages achieved and downstream vendor disclosure, in the form needed for CPCB EPR filings under the Battery Waste Management Rules 2022. Fleets retiring several Mahindra XUV400 EL units should book one consolidated pickup to cut per-pack cost.