2026-09-04

HV Battery (RWD/AWD) (Remove and Replace)

Correction Code 16010102 (RWD), 16010202 (AWD)

Warning
Only technicians who have been trained in High Voltage Awareness and have completed all required certification courses (if applicable) are permitted to perform this procedure. Proper personal protective equipment (PPE) and insulating HV gloves with a minimum rating of class 0 (1000V) must be worn any time a high voltage cable is handled. Refer to Tech Note TN-15-92-003, "High Voltage Awareness Care Points" for additional safety information.
Warning
If the vehicle has air suspension, activate "Jack" mode on the touchscreen before raising and supporting the vehicle.
Warning
Before starting this procedure, make sure that all bolts that attach the battery to the vehicle are installed on the vehicle. Failure to check for missing bolts might result in the battery pack to become loose unexpectedly, and might injure a technician.
Note
Use a cordless electric drill with a 3/8 in drive adapter and an 3/8 in drive air ratchet wrench to perform this procedure. Do not use an impact wrench to remove battery fasteners.
Note
The assistance of another technician is recommended when using the gantry to move the battery packs.

Special tools required for this procedure:

Supplier Part Number Description
Tesla 1020566-00-E BATT MAN LIFT TABLE - MDLS
  • 2026-05-20: Added warnings to never move the gantry with a suspended load or put any part of the body underneath a suspended load. Changed wording to clarify that crates are positioned under gantries rather than gantries moved over crates.
  • 2026-02-25: Added Note to make sure that the vehicle is in Park and EPB Service Mode is not active at the beginning of the procedure.
  • 2026-01-02: Added coolant air purge step for Tegra MCUs. Updated discharge threshold to 25% or 45% depending on region.
  • 2025-08-12: Updated reference to Pyrotechnic Fuse removal procedure.
  • 2025-04-15: Added battery-side RapidMate gasket information.
  • 2025-01-23: Added step to determine if HV battery parameters are within safe limits before removing the pyro disconnect. Added pyro disconnect removal step.
  • 2024-10-31: Updated HV battery discharge steps.
  • 2024-08-16: Added note stating it is not necessary to perform HV disablement.
  • 2024-02-02: Fixed reference error.
  • 2023-11-10: Replaced steps with link to 12V Disconnect procedure.
  • 2023-06-07: Service Engineering updates to the touchscreen steps.
  • 2023-05-22: Updated pack configuration steps.
  • 2023-05-22: Added conspicuous discharge warning table.
  • 2023-03-16: Updated Discharge section and added steps to configure the HV battery.

Discharge

WARNING: To conform with local laws, High Voltage Lithium Batteries must be discharged before packing for shipment. Additionally, HV batteries must be discharged before being put into storage. HV batteries to be shipped must have a State of Charge (SoC) of less than 25% or 45%, depending on the region. If the method of shipment is unknown or uncertain, or the battery is to be stored, it is recommended to discharge the HV battery to less than 25%.

WARNING: After discharge, wait 20 minutes and verify that the SoC is less than the targeted value. This waiting period allows the open circuit voltage (OCV) to settle, which is critical for accurate measurements. Continue discharging if the SoC does not meet the required level.

Make sure to collect all HV battery shipping data using the HV Battery Communication Tool, preferably before removing the HV battery from the vehicle.

WARNING: Do not ship or store an HV battery that has a loss of high voltage isolation. Verify HV battery isolation before packing for shipment or storage. Use the HV Battery Communication Tool, described in Toolbox article #41977 or Customer Document CD-21-16-003, to determine if the HV battery parameters are within safe limits for shipment or storage.
Note
If possible, perform the discharge procedure and collect HV battery shipping data before HV battery removal. This method requires less time and user interaction than to use the Battery Discharge Tool after the battery has been removed. The Battery Discharge Tool can only be used by certified technicians.
Note
The steps of the discharge procedure are mostly touch time, and can be performed by the Service Advisors/Front of House team as well as Service Technicians.
  1. Enable Service Mode Plus. See Service Mode Plus.
  2. Identify the vehicle's current SOC Max: In the Service Mode Plus menu, touch High Voltage > HV Battery, and then touch the large HV battery diagram to display the HV Battery information window.
    • If the SOC Max is less than the SOC shipping threshold, skip to step 6 of this sub-procedure.
    • If the SOC Max is greater than the SOC shipping threshold, continue to the next step.
  3. Move the vehicle to a location where the battery can be safely discharged unattended.
  4. In the Service Mode Plus menu, touch High Voltage > HV Battery.
  5. In the Tools section, touch Start HV Discharge, and then in the window that opens, touch Run.
    Note
    The discharge routine starts and will automatically stop when the SOC Max value for surface transport has been attained.
  6. After discharge is complete, use the HV Battery Communication Tool to collect HV battery shipping data, and then move the vehicle to the service bay.

Removal

  1. Open LH front door.
  2. Lower LH front window.
  3. Raise and support vehicle.
    Note
    Prepare to raise vehicle, Set air suspension to "Jack Mode", Position lift arm pads on vehicle jack pads.
    Note
    Make sure that the vehicle is in Park and EPB Service Mode is not active, otherwise a CAN ECU redeploy will fail at a later stage in this procedure.
  4. Disconnect 12V power. See Disconnect 12V Power.
    Note
    Do not perform HV disablement. It is not required when performing an HV battery remove and replace.
  5. Raise vehicle fully and lower lift onto locks.
    Note
    Set vehicle to comfortable working height, Make sure there's an audible click of the locks on both sides before lowering, otherwise vehicle may tilt to the side.
  6. Remove clips securing LH shear plate to wheel fairing.
    Note
    2x push clips.
  7. Remove LH shear plate.

    15 mm nyloc nut (discard after removal)

    35 Nm (25.8 lbs-ft)

    T25 screws (x3)

    6 Nm (4.4 lbs-ft)

    10 mm bolt

    4 Nm (2.9 lbs-ft)
  8. Repeat the previous 2 steps for the RH shear plate.
  9. Remove clips securing mid aero shield to vehicle.
    Note
    7x push clips.
  10. Remove bolts securing mid aero shield to vehicle.
    Note
    7x bolts, 10mm, 4 Nm.
    4 Nm (2.9 lbs-ft)
  11. Remove mid aero shield from vehicle.
  12. Remove ski side covers on RH side.
    Note
    14x clips, 3x covers.
  13. Remove ski side covers on LH side.
    Note
    14x clips, 3x covers.
  14. Remove front lower bash plate extrusion.
    Note
    2x bolts, T30, 16 Nm.
    16 Nm (11.8 lbs-ft)
  15. Remove and discard four center bolts securing the HV.
    Note
    4x patch bolts, E12.
    38 Nm (28.0 lbs-ft)
  16. Position battery table beneath vehicle.
  17. Lower vehicle to table.
    Note
    Recommend assistance, Align table to vehicle and raise casters to level table if necessary.
  18. Remove and discard the remaining eight center bolts securing the HV battery.
    Note
    8x patch bolts, E12,.
    38 Nm (28.0 lbs-ft)
  19. Remove and discard the front HV battery bolts (x4).
    Tip
    Use of the following tool(s) is recommended:
    • 13 mm socket
    30 Nm (22.1 lbs-ft)
  20. Remove and discard the bolts (x2) securing front of HV battery .
    Tip
    Use of the following tool(s) is recommended:
    • 21 mm socket
    115 Nm (84.8 lbs-ft)
  21. Remove and discard the LH rocker bolts (x8) and the RH rocker bolts (x8).
    Tip
    Use of the following tool(s) is recommended:
    • 13 mm socket
    55 Nm (40.6 lbs-ft)
    Figure 1. LH shown; RH similar
  22. Raise vehicle off of HV battery.
  23. Move battery away from vehicle.
  24. Remove all items from pockets and ensure not wearing metal items.
  25. Inspect HV insulating gloves.
    Note
    Check gloves for damage prior to use, Refer to service document TN-15-92-003
  26. Put on HV insulating gloves and leather over gloves.
  27. Use a multimeter to check voltages at the Rapid Splitter.
    • B+ to ground
    • B- to ground
    • B+ to B-
    Warning
    If any voltage reading is more than 10V, continue to hold the probes to the test points to drop the voltage to 10V. If the voltage does not drop, contact a Field Service Engineer before performing any further work.
  28. Check voltage on HV rapid mate.
    Note
    B+ to ground, B- to ground, and B+ to B-, If any voltage reading is more than 10V, the pack contactors are not fully opened, Contact Engineering for support.
  29. Insert the high voltage RapidMate cover (1038478-00-A) and the low voltage RapidMate cover (1028325-00-A) into the high and low voltage RapidMates.
    Note
    If the covers are not available, use 3M 2480S Masking Tape (2" wide) or 3M 471 Red Vinyl Tape (2” wide) to seal the RapidMates.
  30. Remove leather over gloves and HV insulating gloves.
  31. Install battery coolant service fixture onto coolant rapid mate.
    Note
    Hand tighten nuts while holding fixture down on rapid mate.
  32. Connect the coolant hoses.
    Note
    Drain hose goes into coolant container, Pressure hose connects to regulator.
  33. Connect shop air to regulator.
    Note
    Make sure regulator valve is closed prior to connecting shop air.
  34. Slowly open valve on pressure regulator and allow coolant to drain out of HV battery return hose.
    Note
    Close valve on pressure regulator once no coolant is draining from HV battery return hose into coolant container.
  35. Remove shop air and pressure hose from regulator.
  36. Remove the pyrotechnic battery disconnect prior to shipping the HV battery. See Fuse - Pyrotechnic - HV Battery 1.0/1.5 (Remove and Install) or Fuse - Pyrotechnic - HV Battery 2.0 (Remove and Install).
  37. Attach HV battery H-frame to gantry and raise into position.
    Warning
    Never stand or place any part of your body underneath a suspended load.
    Warning
    Never attempt to move a gantry while a load is suspended.
    Warning
    Refer to the gantry manufacturer's instructions for safety and operational information.
  38. Position HV battery under gantry.
    Note
    Recommend assistance.
  39. Lower H-frame onto HV battery and secure H-frame to battery.
    Note
    4x hooks.
  40. Raise HV battery off of battery table.
  41. Position the pallet underneath the gantry.
    Note
    Recommend assistance.
  42. Lower HV battery onto pallet.
  43. Remove H-frame from old HV battery.
    Note
    4x hooks.
  44. Raise gantry and H-frame from old HV battery.

Installation

Note
Heed the following conditions when installing the replacement HV battery, particularly for vehicles built before April 10, 2016:
  • If the replacement HV battery part number is 1014116-00-xxx or later, inspect both upper rear suspension links:
    • If the part numbers are 1027426-00-C (Dual Motor) or later, or 1027421-00-E (RWD) or later, the links are up-to-date and do NOT need to be replaced.
    • If the part numbers are earlier than 1027426-00-C (Dual Motor), or 1027421-00-E (RWD), replace the links with part numbers 1027426-00-C (Dual Motor) or 1027421-00-E (RWD) or later. See Link - Suspension - Rear - Upper - LH (Remove and Replace).
  • Model S Built Before April 10, 2016 : Perform a visual inspection of the HV Rapid Mate:
    Note
    Refer to TN-13-16-001, "Rapid Mate Inspection" for more information.
    1. Visually inspect the skirt seal on the vehicle-side HV Rapid Mate for damage or deformation. If there is damage or deformation, replace the Rapid Mate seal (refer to procedure).
    2. Visually inspect the blades, pins, and plastic insulator on the vehicle-side HV Rapid Mate for corrosion or damage. If there is damage or deformation, replace the vehicle-side HV Rapid Mate (refer to procedure).
    3. If necessary, clean the blades, pins, and plastic insulator on the vehicle-side HV Rapid Mate with alcohol wipes, and allow the alcohol to completely dry.
    4. Use a swab to apply P-80 emulsion to the outside of the main seal and the inside of the skirt seal on the vehicle-side HV Rapid Mate.

  • Inspect the Rapid Mate gasket and choose the appropriate procedure based on the vehicle's date of manufacture:
    Note
    If the gasket(s) must be replaced/swapped, note the fastener spec: T25, 2.8 Nm.
    2.8 Nm (2.1 lbs-ft)
    Vehicles built through April 10, 2016, use the shorter Rapid Mate gasket, PN 1041311-00-BVehicles built after April 10, 2016 use the longer Rapid Mate gasket, PN 1055957-00-C
  1. Open the crate top housing the new HV battery pack.
    Note
    Recommend assistance.
  2. Position the new HV battery crate underneath the gantry and secure the H-frame to battery.
    Note
    4x hooks, Recommend assistance.
  3. Lift new HV battery out of crate.
  4. Move the HV battery crate, then move the HV battery table underneath the gantry.
    Note
    Recommend assistance.
  5. Lower HV battery onto battery table.
    Note
    Recommend assistance, Make sure to align HV battery center to battery table.
  6. Release H-frame from HV battery and raise gantry.
    Note
    4x hooks.
  7. Remove the HV battery from under gantry.
    Note
    Recommend assistance.
  8. Position the old HV battery underneath the gantry.
    Note
    Recommend assistance.
  9. Lower H-frame onto old HV battery and secure H-frame to battery.
    Note
    4x hooks.
  10. Raise old HV battery above height of HV battery crate.
  11. Position HV battery crate underneath the old HV battery.
  12. Lower old HV battery into crate.
    Note
    Use caution to align HV battery into crate and not damage the battery, Recommend assistance.
  13. Remove H-frame from old HV battery.
    Note
    4x hooks.
  14. Raise gantry and H-frame from old HV battery.
  15. Lower gantry and remove HV battery H-frame from gantry.
  16. Close crate top housing old HV battery.
    Note
    Recommend assistance.
  17. Install battery coolant service fixture onto coolant rapid mate.
    Note
    Hand tighten nuts while holding fixture down on rapid mate.
  18. Fill the fluid evacuator with coolant.
    Note
    Fill 8L of coolant.
  19. Connect air hose to fluid evacuator and set the tool to vacuum hose position.
    Note
    Verify both the pressure and relief valves are closed.
  20. Pressurize and fill battery.
    Note
    Open pressure valve and hand pump pressure using Mityvac.
  21. Close the pressure valve on the evacuator.
  22. Disconnect air hose from fluid evacuator .
  23. Remove tool from battery pack.
  24. Position HV battery underneath vehicle.
  25. Put on HV insulating gloves and leather over gloves, and do not remove them until the HV battery is mated with the vehicle.
  26. Remove covers or tape from LV and HV Rapid Mates.
  27. Lower vehicle onto pack.
    Warning
    There may be residual high voltage at the RapidMate connector which might arc when inspecting the connection there.
    Note
    Align Rapid Mate connections before lowering fully, Recommend assistance.
  28. Remove leather over gloves and HV insulating gloves.
  29. Install but do not torque the new HV battery front patch bolts (x4).
    Tip
    Use of the following tool(s) is recommended:
    • 13 mm socket
  30. Install but do not torque the new front corner HV battery bolts (x2) .
    Tip
    Use of the following tool(s) is recommended:
    • 21 mm socket
  31. Install but do not torque the new outer center patch bolts (x8).
    Tip
    Use of the following tool(s) is recommended:
    • External Torx E12
  32. Install but do not torque the new LH and RH rocker patch bolts (x8 per side).
    Tip
    Use of the following tool(s) is recommended:
    • 13 mm socket
  33. Torque remaining HV battery bolts.
    Note
    2x bolts, 21mm, 115 Nm, 4x patch bolts, 13mm, 30 Nm.

    Outer center bolts (x8) - E12

    38 Nm (28.0 lbs-ft)

    Front patch bolts (x4) - 13 mm

    30 Nm (22.1 lbs-ft)

    Front corner bolts (x2) - 21 mm

    115 Nm (84.8 lbs-ft)
    Figure 2. Outer center bolts (x8)
    Figure 3. Front bolts (x4) - 13 mm
    Figure 4. Front corner bolts (x2) - 21 mm
  34. Raise vehicle and remove battery table.
    Note
    Recommend assistance.
  35. Install new inner center HV battery bolts (x4).
    Tip
    Use of the following tool(s) is recommended:
    • External Torx E12
    CAUTION
    Do not over tighten bolts.
    38 Nm (28.0 lbs-ft)
  36. Torque the inner center HV battery bolts.
    Note
    4x patch bolts, E12, 38 Nm.
    38 Nm (28.0 lbs-ft)
  37. Install front lower bash plate extrusion. Install and torque patch bolts (x2).
    Tip
    Use of the following tool(s) is recommended:
    • Torx T30 socket
    16 Nm (11.8 lbs-ft)
  38. Install ski side covers onto RH side of HV battery.
    Note
    14x clips, 3x covers.
  39. Install ski side covers onto LH side of HV battery.
    Note
    14x clips, 3x covers.
  40. Position mid aero shield and install bolts securing mid aero shield to vehicle.
    Note
    7x bolts, 10mm
    4 Nm (2.9 lbs-ft)
  41. Install clips securing mid aero shield to vehicle.
    Note
    7x push clips.
  42. Install screws, bolt, and nut securing RH shear plate to vehicle.

    15 mm nyloc nut (discard after removal)

    35 Nm (25.8 lbs-ft)

    T25 screws (x3)

    6 Nm (4.4 lbs-ft)

    10 mm bolt

    4 Nm (2.9 lbs-ft)
  43. Install clips securing RH shear plate to wheel fairing.
    Note
    2x push clips.
  44. Repeat the previous 2 steps for the LH shear plate.
  45. Lower vehicle partially.
  46. Reconnect First Responder Loop and 12V negative terminal.
    Note
    1x nut, 10mm, 5 Nm, 1x connector.
    5 Nm (3.7 lbs-ft)
  47. Connect 12V charger.
    Note
    The vehicle 12V system must remain supported until vehicle firmware is completed.
  48. Connect a laptop to the diagnostic port of the vehicle, and then use Toolbox 3 to locally connect to the vehicle. See Toolbox 3 (Connect and Disconnect).
  49. If the vehicle is equipped with an Intel Atom MCU and vehicle software 2023.20 or newer, go to step 56. Otherwise, continue to the next step.
  50. In Toolbox 3, click the Actions tab, type "Service Redeploy" into the search field, click UPDATE_CAN-REDEPLOYvia Service Mode Plus:
    • Drive Inverter Replacement ➜ Drive Inverter DIRE1L Replacement ➜ CAN Redeploy
    • Drive Inverter Replacement ➜ Drive Inverter DIRE1R Replacement ➜ CAN Redeploy
    • Drive Inverter Replacement ➜ Drive Inverter DIRE2 Replacement ➜ CAN Redeploy
    • Drive Inverter ➜ Front Drive Inverter Replacement ➜ CAN Redeploy
    • Drive Inverter ➜ Rear Drive Inverter Replacement ➜ CAN Redeploy
    • Drive Inverter ➜ Rear Left Drive Inverter Replacement ➜ CAN Redeploy
    • Drive Inverter ➜ Rear Right Drive Inverter Replacement ➜ CAN Redeploy
    • Drive Unit ➜ Front Drive Unit Replacement ➜ CAN Redeploy
    • Drive Unit ➜ Rear Drive Unit Replacement ➜ CAN Redeploy
    • Thermal ➜ HVAC ➜ CAN Redeploy
    • chassis ➜ DPB Post Replacement ➜ CAN Redeploy
    • chassis ➜ ESP Post Replacement ➜ CAN Redeploy
    • chassis ➜ IDB Post Replacement ➜ CAN Redeploy
    • chassis ➜ RCU Post Replacement ➜ CAN Redeploy
    • chassis ➜ ESP Replacement Panel ➜ CAN Redeploy
    • chassis ➜ IBST Replacement Panel ➜ CAN Redeploy
    via Toolbox:(link)    , click Run, and allow the routine to complete.
  51. Unlock the vehicle gateway for diagnostic communication, if not already unlocked. See Gateway Unlock.
  52. In Toolbox 3, click the Actions tab, type "Pack Replacement" into the search field, click PROC_BMS_X_PACK-REPLACEMENTvia Service Mode Plus:High Voltage Battery ➜ High Voltage Battery Replacement ➜ High Voltage Battery Replacement Routinevia Toolbox:(link), click Run, and allow the routine to complete.
  53. In Toolbox 3, click the Actions tab, type "Standby Reboot Gtw" into the search field, click PROC_ICE_X_STANDBY-REBOOT-GTWvia Toolbox:(link), click Run, and allow the routine to complete.
  54. In Toolbox 3, click the Actions tab, type "Coolant air purge" into the search field, click PROC_THC_X_COOLANT-AIR-PURGEvia Service Mode:Thermal ➜ Actions ➜ Coolant Air Purgevia Toolbox:(link), click Run, and allow the routine to complete.
  55. Go to step 63.
  56. Enable Service Mode Plus. See Service Mode Plus.
  57. On the vehicle touchscreen, touch Lightning Bolt icon > Procedures.
  58. Under After High Voltage Battery Replacement, touch CAN ECU Redeploy, in the window that opens, touch Run, and then wait for completion.
  59. Disconnect the First Responder Loop.
  60. Unlock the vehicle gateway for diagnostic communication, if not already unlocked. See Gateway Unlock.
  61. In the High Voltage Battery Replacement window, under After High Voltage Battery Replacement, touch High Voltage Battery Replacement Routine, in the window that opens, touch Run, and then wait for completion.
  62. Disable Service Mode Plus. See Service Mode Plus.
  63. Connect the First Responder Loop.
  64. In Toolbox 3, click the Actions tab, type "Coolant air purge" into the search field, click PROC_THC_X_COOLANT-AIR-PURGEvia Service Mode:Thermal ➜ Actions ➜ Coolant Air Purgevia Toolbox:(link), click Run, and allow the routine to complete.
  65. Disconnect the laptop with Toolbox 3 from the vehicle. See Toolbox 3 (Connect and Disconnect).
  66. Disconnect 12V charger from vehicle.
  67. Perform a steering wheel scroll wheel reset.
  68. Install HEPA filter outlet duct.
  69. Install HEPA filter inlet duct.
    Note
    2x tabs, One on each side.
  70. Install clips securing HEPA filter inlet duct to cowl panel.
    Note
    3x push clips.
  71. Secure drainage hoses to HEPA filter inlet duct.
    Note
    2x hoses.
  72. Install LH underhood apron.
    Note
    9x clips.
  73. Install RH underhood apron.
    Note
    9x clips.
  74. Install rear underhood apron.
    Note
    8x clips.
  75. Close hood .
    Note
    Press firmly in green highlighted areas (see image), Damage may result from pressure elsewhere on hood.
  76. Remove vehicle from lift.
    Note
    Lower rack arms fully and remove them from under vehicle, Remove air suspension from "Jack Mode" via Controls > Service > '' JACK MODE'' .
  77. Raise LH front window.
  78. Close LH front door.