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am I screwed?
Any advise?
I've had modules like that and they were fine when reassembled :)

In the past when I was storing Leaf modules I would typically create a pile of ten and use their own weight to minimise 'bulging'. I would rotate the members within the pile once a week so that the top module became the bottom. I did this simply because I found it much easier to assemble packs when the modules weren't bulging.

I would suggest putting them in piles and rotating the members for a couple of weeks and assuming the bulging improves assemble them into your new packs at the correct pressure. As a precaution I would also suggest you keep the modules away from the house and check temperatures on a regular basis just incase something else is going on.

That said 4.03V is ~85% SOC so I think you're ok.
 

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So you're saying face the two side that's bulge up against each other? I assumed if I reassembled it back together now without letting it sit and adjust itself would be a super bad idea? Since I would physically push against the cells instantly and do some damage?
Once you release the pressure by disassembling the pack all Leaf modules bulge to some extent. Trying to reassemble the pack can be very challenging without minimising the bulging and while we did that on the first pack we built we developed a procedure to use time and weight to minimise the problem on later packs. So, yes place the two bulging sides against one another and build a stack of ten modules... then wait a week and rotate the modules.

I was thinking to pull apart the aluminum shell on the damaged corner cells that I will not be using... to see if the lithium cells are puff? good idea?
Sure, it's easy (see here). Just be extremely cautious about shorting the terminals... I did it once and had molten steel and copper flying around :eek:
 
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