2026-08-09

HV Connector - Busbar - Charge Port (Standard) (Remove and Install)

Correction code NEW NOTE: Unless otherwise explicitly stated in the procedure, the correction code and its associated FRT reflect all of the work required to perform this procedure, including the linked procedures. Do not stack correction codes unless explicitly told to do so. NOTE: See Flat Rate Times to learn more about FRTs and how they are created. NOTE: See Personal Protection to make sure you are wearing proper PPE when performing the procedure below. NOTE: See Ergonomic Precautions for safe and healthy working practices.

Warning
This procedure is a DRAFT. Although it has been validated, Warnings and Cautions might be missing. Follow safety requirements and use extreme caution when working on or near High Voltage systems and components.
Warning
Cybertruck electronics are powered by a 48V "mid voltage" or "MV" architecture that is designed to improve efficiency. Servicing MV components requires extra knowledge and care in order to avoid personal and/or vehicular harm. Read and understand MV precautions in Electrical Precautions and make sure any required MV-related training courses have been completed, as applicable.
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 at all times a high voltage cable, busbar, or fitting is handled. Refer to Tech Note TN-15-92-003, High Voltage Awareness Care Points for additional glove and safety information.
  • 2026-05-08: Released new procedure.
  1. Open the LH front door and lower the LH front window.
  2. Remove the tonneau slats. See Slat System - Tonneau (Remove and Install).
  3. Raise and support the vehicle. See Raise Vehicle - 2 Post Lift.
  4. Open the tonneau cover.
  5. Open the tailgate.
  6. Remove the bed floor assembly. See Bed Floor Assembly (Long Range) (Remove and Install).
  7. Remove the NVH barrier. See Tonneau NVH Barrier Assembly (Remove and Install).
  8. Disconnect MV power. See Mid-Voltage Power (Disconnect and Connect) (Modify).
  9. Secure RDU header connector to ancillary
    Note
    1x connector, Verify lever is in the upright and open position, Carefully seat connector and allow lever to engage, Fully secure lever and verify red tab is locked, Do not damage any pins
  10. Lower vehicle until tires are touching the ground
    Note
    Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
  11. Remove bolt securing busbar HV connector lid
    Note
    1x bolt, EP10, 9 Nm
  12. Remove bolts securing HV connector to DC FC header
    Note
    2x bolts, 10mm, 9 Nm
  13. Release HV connector from DC FC header
    Note
    1x connector, Use inflatable airbag if needed to suspend busbar assembly above ancillary assembly
  14. Raise CP busbar connector
    Note
    2x inflatable bags, Install bags, Do not open tonneau to prevent damage
  15. Remove screws securing HV connector to CP busbars
    Note
    2x screws, T20, 1.5 Nm, Position mirror as needed
  16. Remove HV connector from CP busbars
    Note
    Gently pry between orange clips and primary heat sink, Pull evenly
  17. Position HV connector onto CP busbars
    Note
    Push evenly, Make sure orange clips are flush with primary heat sink
  18. Install screws securing HV connector to CP busbars
    Note
    2x screws, T20, 1.5 Nm, Position mirror as needed
  19. Clean HV connector contact surface of residual Penetrox
    Note
    Allow 1 minute dry time after removing Penetrox, New busbar comes with Penetrox applied to HV connector
  20. Apply Penetrox onto HV connector joints
    Note
    Apply 2 drops of Penetrox A-13 about 5mm in diameter to either side of the hole on both leads, Spread evenly to verify the contact surface is fully covered
  21. Clean busbar HV connector contact surface of residual Penetrox
    Note
    Allow 1 minute dry time after removing Penetrox, It is necessary to clean HV connector during re-use of busbar
  22. Lower CP busbar connector
    Note
    2x inflatable bags, Remove bags, Do not open tonneau to prevent damage
  23. Position busbar connector and lower onto HV header
    Note
    Release bungee cord
  24. Install bolts securing charge port busbar kit to HV Header
    Note
    2x bolts, 10mm, 9 Nm
  25. Perform Hioki resistance test at each HV joint from HV busbar lead to bolt head
    Note
    2x HV joints, When using Hioki tester, verify the meter has been properly adjusted and set prior to usageThe acceptable resistance is between 0.050 mΩ (50 μΩ) and 0.195 mΩ (195 μΩ).If the resistance is greater than 0.195 mΩ (195 μΩ), stop work and escalate the Toolbox session.If the resistance is lower than 0.050 mΩ (50 μΩ), reposition the probes and measure again.If the resistance is repeatedly between 0.00 mΩ and 0.050 mΩ (50 μΩ), hioki test passed, proceed to next step
  26. Install bolt securing busbar HV connector lid
    Note
    1x bolt, EP10, 9 Nm
  27. Reconnect MV power. See Mid-Voltage Power (Disconnect and Connect) (Modify).
  28. Install the NVH barrier. See Tonneau NVH Barrier Assembly (Remove and Install).
  29. Install the bed floor assembly. See Bed Floor Assembly (Long Range) (Remove and Install).
  30. Install the rear underhood apron. See Underhood Apron - Rear (Remove and Install).
  31. Close the tonneau cover.
  32. Close the tailgate.
  33. Install the rear skid plate. See Skid Plate - Rear (Remove and Install).
  34. Install the rear underhood apron. See Underhood Apron - Rear (Remove and Install).
  35. Install the tonneau slats. See Slat System - Tonneau (Remove and Install).