23/07/2024 17:25:13

Device Cluster Assembly (Remove and Install)

Correction code 1630010111 1630010112 FRT 3.06 NOTE: Unless otherwise explicitly stated in the procedure, the above correction code and 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. To provide feedback on FRT values, email LaborTimeFeedback@tesla.com. NOTE: See Personal Protection to make sure wearing proper PPE when performing the below procedure.

2024-05-14: Added install/remove steps for ancillary access bench.
2024-04-03: Added check and remedy for last mile busbar misalignment in insulator plastic tray.
2024-03-25: Cleaned up topic

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. Provide corrections and feedback to ServiceDevelopment@teslamotors.com.

Remove

Raise and support the vehicle. See Raise Vehicle - 2 Post Lift.
Remove the tonneau slats. See Slat System - Tonneau (Remove and Install).
Place the vehicle into Service Mode. See Service Mode.
Remove the bed floor assembly. See Truck Bed - Bed Floor Assembly (Remove and Install).
Remove the bolts (x6) that attach the RH tonneau NVH cover.
5 Nm (3.7 lbs-ft)
Tip: Use of the following tool(s) is recommended:
- 10 mm socket
Note
2-peice NVH assembly order of operations requires RH side to be released first to allow busbar clearance for LH side removal.
Remove the RH tonneau NVH cover.

Note
Release rearward, and then slide over the LH side NVH cover before removing upward.
Remove the bolts (x5) that attach the LH tonneau NVH cover.
5 Nm (3.7 lbs-ft)
Tip: Use of the following tool(s) is recommended:
- 10 mm socket
Remove the LH tonneau NVH cover.

Note
Slide towards the center. Ensure busbar clearance during removal to avoid damage to the NVH material.
Remove the screws (x8) that attach the tonneau coverbox cross supports.
5 Nm (3.7 lbs-ft)
Tip: Use of the following tool(s) is recommended:
- Torx T25 socket
Clean all debris from the ancillary cover.

Note
During the removal of the ancillary cover, any debris on top of the cover may be deposited into the ancillary bay.
Release the pressurize pack air line from the ancillary.

Note
x1 connector

CAUTION
Do not release air line to the reservoir. Rapid loss of pressure will result if the wrong air line is released.
Remove the VOSS fitting from the pressurize pack air line to the ancillary.

Note
x1 VOSS fitting

Note
Slide the threaded section back, remove the collet, and then slide the threaded section off of air line. Discard after removal.
Disconnect the electrical connector, and then remove the bolt that attaches the pressurize pack valve block to the air suspension reservoir.
5 Nm (3.7 lbs-ft)
Tip: Use of the following tool(s) is recommended:
- 10 mm socket
Note
x1 clip, x1 zip tie

Note
Release the lock before disengaging the connector.

Note
Cut the zip tie at the reservoir/ancillary air line bundle.

Note
Release the harness clip at the bracket.
Release the air suspension valve block.

Note
x3 rubber grommets

Note
Rotate clockwise until the top 2 rubber feet have released from the bracket. Pull upwards at a 45 degree angle to release the bottom rubber foot from the bracket.

Note
Leave all air lines and connections secured, and then set the assembly aside.
Remove the nuts (x2) that attach the air suspension reservoir to the body.
33 Nm (24.3 lbs-ft)
Tip: Use of the following tool(s) is recommended:
- 13 mm socket
Note
x2 fir tree clips
Put the air suspension reservoir in service position, and then install the Ancillary Access Bench (2035746-00-A).

Note
Raise and swing the air suspension reservoir to the side of the bed.
Open the powered frunk.
Remove the rear underhood apron. See Underhood Trim - Rear Apron Assembly (Remove and Install).
Disconnect MV power. See Disconnect MV Power.
Perform Vehicle HV Disablement procedure. See Vehicle HV Disablement Procedure.
Disconnect the pressurized pack lines.

Note
x2 VOSS fittings, 12 mm, 8 Nm. Discard and replace the VOSS fittings.
Remove the VOSS fitting from pressurized pack air lines.

Note
x2 VOSS fitting

Note
Slide the threaded section back, remove the collet, and then slide the threaded section off of air line. Discard after removal.
Remove the pyro access cover. See High Voltage Battery Assembly - Pyro Access Cover, HVB (Remove and Install).
Remove the primary and secondary pyro fuses. See Disconnect, Pyro (Remove and Install).
Release the HV connectors (x2) at the 2x4 header.

Note
Fully release the red lock tab. Pull the black latch down to release the connector.
Release the 2x4 header assembly.
6 Nm (4.4 lbs-ft)
Tip: Use of the following tool(s) is recommended:
- 5-lobe E-Torx 10 mm
Release the drive unit electrical connectors (x3) from the ancillary headers.

Note
Release the blue lock tab. Rotate the black latch.
Remove the bolts (x6) that attach the HC-Stak HV headers for the LH RDU, FDU, and RH RDU from the ancillary flange.
10 Nm (7.4 lbs-ft)
Tip: Use of the following tool(s) is recommended:
- 5-lobe E-Torx 10 mm
Remove the LH RDU, FDU, and RH RDU headers from the ancillary flange.

Note
No tools required.

Note
Inspect the header seals. Replace the header if damaged.
Lower the vehicle until the tires are touching the ground.
Disconnect the ancillary bay MV electrical connector.

Note
Double locking: Release the tab, and then pivot the lever. Release the second tab to disengage the electrical connector. Wait 1 second between locking tab release to discharge and prevent arcing.
Remove the bolt that attaches the busbar HV connector lid.
9 Nm (6.6 lbs-ft)
Tip: Use of the following tool(s) is recommended:
- 10 mm socket
Remove the bolts (x2) that attach the HV connector to the DC FC header.
9 Nm (6.6 lbs-ft)
Tip: Use of the following tool(s) is recommended:
- 10 mm socket
Release the HV connector from the DC FC header, and then use an inflatable airbag to suspend the busbar assembly above the ancillary assembly.

Note
Upon separation, check for grease around the inner perimeter of the DC FC header. If present, additional steps will need to be performed later.
Support the HV busbar assembly to maintain clearance with a bungee cord.
Remove the bolts (x2) that attach the fast charger header doubler.
10 Nm (7.4 lbs-ft)
Tip: Use of the following tool(s) is recommended:
- External Torx E10 5-Lobe
Remove the bolts (x2) that attach the low voltage header.
6 Nm (4.4 lbs-ft)
Tip: Use of the following tool(s) is recommended:
- 10 mm socket
Remove the ancillary cover. See Ancillary Cover (Remove and Install).
Remove the DC header.

Note
Slide the header off the DC bus links.

Note
Inspect the seal. Replace the header if damaged.
Remove the ancillary bay harness. See Harness - Ancillary Bay (Remove and Replace).
Disconnect the HVC harness electrical connector from the PCS.

Note
Release the connector lock. Press the lever and pull at connector. Do not pull at the harness.
Remove the device cluster busbar bolts (x4).
Tip: Use of the following tool(s) is recommended:
- Torx Plus 55
Note
Torque: 5 Nm + 60 degrees

Note
Captured bolts with insulated covers.
Remove the device cluster assembly bolts (x4).
6 Nm (4.4 lbs-ft)
Tip: Use of the following tool(s) is recommended:
- External Torx E10 5-Lobe
Remove the device cluster from the ancillary tray.

Warning
Make sure to wear Personal Protection Equipment (PPE) such as HV gloves and safety glasses when working on HV component.

Note
Put the device cluster on a stand to protect the headers at the bottom of the assembly.

Note
Remove the lifting/install tool.

Install

Inspect the condtion of the last mile busbar in its insulator plastic tray, that the busbar is fully seated in the tray with the swaged nut in the black tube, and not misaligned.

Figure 1. Arrows indicating misalignment with an increasing gap between the busbar and tray, and the swaged nut is offset from the tube.
If the insulator tray has a retention hook, make sure that the busbar is secured to the tray by the retention hook.

Figure 2. Arrows indicating alignment with a minimum gap between the busbar and tray, and the swaged nut is inside the tube.
If the tray does not have a retention hook, or the hook is broken, secure the busbar to the tray with a cable tie in the location shown.

Note
Make sure to trim excess cable tie.

Figure 3. Arrows indicating alignment with a minimum gap between the busbar and tray, and the swaged nut is inside the tube.
Install the device cluster onto the ancillary tray.

Warning
Make sure to wear Personal Protection Equipment (PPE) such as HV gloves and safety glasses when working on HV component.

Note
Align the datums and headers to ancillary, and then slowly lower the device cluster into place.

Note
Avoid contact of the drive unit headers to the ancillary tray.
Fasten the device cluster assembly bolts (x4).
6 Nm (4.4 lbs-ft)
Tip: Use of the following tool(s) is recommended:
- External Torx E10 5-Lobe
Fasten the device cluster busbar bolts (x4).
Tip: Use of the following tool(s) is recommended:
- Torx Plus 55
Note
Torque: 5 Nm + 60 degrees

Note
Captured bolts with insulated covers.
Perform Hioki measurements from the device cluster assembly and the busbar bolts.

Note
x1 bolt, E10 5 lobe Torx, 6 Nm; x4 bolts, Torx Plus 55, 5 Nm + 60 degrees

Note
Perform a zero adjust to the Hioki meter prior to testing.

Note
Use the diagram in images to find probing locations and the reading specifications to look for.

Note
LSL means Lower Specification Limit. USL means Upper Specification Limit.

Note
1020_301 | T1 LSL 0.002 mΩ (2 μΩ) - USL 0.05 mΩ (50 μΩ)

Note
1020_304 | POS Contactor LSL 0.002 mΩ (2 μΩ) - USL 0.05 mΩ (50 μΩ)

Note
1010_603 | HVC Ground strap LSL 0.35 mΩ (350 μΩ) - USL 0.78 mΩ (780 μΩ)

Note
1020_303 | Shunt2 LSL 0.003 mΩ (3 μΩ) - USL 0.05 mΩ (50 μΩ)

Note
1020_302 | Shunt1 LSL 0.003 mΩ (3 μΩ) - USL 0.05 mΩ (50 μΩ)

CAUTION
If readings are lower than the LSL numbers, you are not probing correctly. If readings are higher than USL numbers, you have bolts that are not torqued correctly or connectors that may be softset or have internal connector issues.
Secure the HVC harness electrical connector to the PCS.

Note
Secure the connector lock.
Install the ancillary bay harness. See Harness - Ancillary Bay (Remove and Replace).
Install the DC header.

Note
Slide the header onto the DC bus links.

Note
Inspect the seal. Replace the header if damaged.
Install the ancillary cover. See Ancillary Cover (Remove and Install).
Remove leather over gloves and HV insulating gloves.
Install the screws (x8) that attach the tonneau coverbox cross supports.
5 Nm (3.7 lbs-ft)
Tip: Use of the following tool(s) is recommended:
- Torx T25 socket
Note
Supports install in the same direction of the fasteners.
Install the LH tonneau NVH cover.

Note
Make sure the busbar clearance during installation to avoid damage to the NVH material.
Install the bolts (x5) that attach the LH tonneau NVH cover.
5 Nm (3.7 lbs-ft)
Tip: Use of the following tool(s) is recommended:
- 10 mm socket
Install the RH tonneau NVH cover.
Install the bolts (x6) that attach the RH tonneau NVH cover.
5 Nm (3.7 lbs-ft)
Tip: Use of the following tool(s) is recommended:
- 10 mm socket
Remove the Ancillary Access Bench, and then put the air suspension reservoir into position for installation.
Install the nuts (x2) that attach the air suspension reservoir.
33 Nm (24.3 lbs-ft)
Tip: Use of the following tool(s) is recommended:
- 13 mm socket
Note
x2 fir tree clips
Secure the air suspension valve block.

Note
x3 rubber grommets

Note
Rotate counterclockwise until the top 2 rubber feet are secured onto the bracket. Push downwards at a 45 degree angle to secure the bottom rubber foot into bracket.

Note
Position air lines and connections into place for installation.
Install a new VOSS air fitting to the pressurize pack valve block at the ANC circuit.
8 Nm (5.9 lbs-ft)
Tip: Use of the following tool(s) is recommended:
- 12 mm socket
Note
x1 VOSS fitting

Note
Do not remove the VOSS plastic plug until the pressurize pack line install.
Secure the pressurize pack air line from the ancillary to the valve block.

Note
x1 line

Note
Remove the plastic cap from the VOSS fittings. Press the air lines into the fitting until the mark aligns with the top of the fitting. Verify the line is properly secured by performing a push-pull test.
Install the bolt that attaches the pressurize pack valve block to the air suspension reservoir, and then connect the electrical connector.
5 Nm (3.7 lbs-ft)
Tip: Use of the following tool(s) is recommended:
- 10 mm socket
Note
x1 clip, x1 zip tie

Note
Secure the reservoir and ancillary air lines at the white marked sections.
Install the bed floor assembly. See Truck Bed - Bed Floor Assembly (Remove and Install).
Fully raise the vehicle.
Inspect the HV insulating gloves.

Note
Check gloves for damage prior to use. Refer to service document TN-15-92-003 for information on inspecting the HV gloves.
Put on the HV insulating gloves and leather over gloves.
Install the LH RDU, FDU, and RH RDU headers to the ancillary flange.

Note
No tools required.

Note
Inspect the header seals. Replace the header if damaged.
Fasten the bolts (x6) to the HC-Stak HV headers for the LH RDU, FDU, RH RDU to the ancillary flange.
10 Nm (7.4 lbs-ft)
Tip: Use of the following tool(s) is recommended:
- 5-lobe E-Torx 10 mm
Fasten the 2x4 header assembly bolts (x4).
6 Nm (4.4 lbs-ft)
Tip: Use of the following tool(s) is recommended:
- 5-lobe E-Torx 10 mm
Note
Confirm the alignment of the assembly with the fastener openings.
Connect the HV electrical connectors (x2) at the 2x4 header.

Note
Fully engage the red lock tab.
Connect the drive unit electrical connectors (x3) to the ancillary headers.

Note
Rotate the black latch.

Note
Ensure the blue locking tab is fully engaged.
Clean the mating surface of the pyro.

Note
Use a non-conductive plastic tool to clean the busbar side. Allow 1 minute for the Isopropyl Alcohol (IPA) to fully dry.

CAUTION
Do not use any other types of cleaner.
Install the primary and secondary pyro fuses. See Disconnect, Pyro (Remove and Install).
Remove the leather over gloves and HV insulating gloves.
Install the bolts (x4) that attach the pyro fuse access cover.
10 Nm (7.4 lbs-ft)
Tip: Use of the following tool(s) is recommended:
- External Torx E10 5-Lobe
Note
Make sure that the seal is fully seated and undamaged.
Install the pressurized pack lines (x2).
8 Nm (5.9 lbs-ft)
Tip: Use of the following tool(s) is recommended:
- 12 mm 6 point flare nut wrench
- 12 mm flare nut crowfoot socket
Note
x2 VOSS fittings

Note
Remove the plastic caps from the VOSS fittings. Press the air lines into the fitting until the mark aligns with the top of the fitting. Verify the line is properly secured by performing a push-pull test.
Install the mid aero shield.

Note
x6 clips; x3 bolts, 15 mm, 42 Nm; x5 bolts, 13 mm, 28 Nm; x2 bolts, 10 mm, 6 Nm

Note
Apply Loctite 222 onto mid aero shield bolts and install the fasteners.
Fully lower the vehicle.
Connect MV power. See Disconnect MV Power.
Install the rear underhood apron. See Underhood Trim - Rear Apron Assembly (Remove and Install).
Close the powered frunk.
Install the tonneau slats. See Slat System - Tonneau (Remove and Install).
Remove the vehicle from the lift. See Raise Vehicle - 2 Post Lift.