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.

1. Stage vehicle behind lift
   Note

   Position vehicle behind lift ensuring all four doors have enough clearance to open fully

   

2. Open all the doors and lower all the windows.
3. Manually latch all doors to prevent lockout
   Note

   Engage latch with screwdriver

   

4. Remove the rear underhood apron. See Underhood Apron - Rear (Remove and Install).
5. Place the vehicle into Service Mode. See Service Mode.
6. Unlock the vehicle Gateway. See Gateway (Unlock).
7. Run ODIN routine PROC_RCM_DISARMvia Service Mode Plus:
   • Safety & Restraints ➜ Airbags ➜ Disarm RCM
   • Safety & Restraints ➜ Seats ➜ Disarm RCM
   via Toolbox:(link)
8. Remove the tonneau slats. See Slat System - Tonneau (Remove and Install).
9. Remove the LH rocker panel assembly. See Rocker Panel Assembly - LH (Remove and Install).
10. Remove the LH front rocker step reinforcement. See Rocker Step Reinforcement - Front - LH (Remove and Install).
11. Remove the LH rear rocker step reinforcement. See Rocker Step Reinforcement - Rear - LH (Remove and Install).
12. Remove the RH rocker panel assembly. See Rocker Panel Assembly - LH (Remove and Install).
13. Remove the RH front rocker step reinforcement. See Rocker Step Reinforcement - Front - LH (Remove and Install).
14. Remove the RH rear rocker step reinforcement. See Rocker Step Reinforcement - Rear - LH (Remove and Install).
15. Move LH front seat backward
16. Remove bolts securing front of LH front seat tracks to risers
    Note

    2x patch bolts, T45P, 34 Nm, Discard after removal

    

17. Raise and move LH front seat forward
18. Remove bolts securing rear of LH front seat tracks to floor
    Note

    2x patch bolts, T45P, 34 Nm, Discard after removal

    

19. Adjust position of LH front seat for easy removal
    Note

    Move seat to middle of track at most upright position with seat fully up off floor
20. Move RH front seat backward
21. Remove bolts securing front of RH front seat tracks to risers
    Note

    2x patch bolts, T45P, 34 Nm, Discard after removal

    

22. Move RH front seat forward
23. Remove bolts securing rear of RH front seat tracks to floor panel
    Note

    2x patch bolts, T45P, 34 Nm, Discard after removal

    

24. Adjust position of RH front seat for easy removal
    Note

    Move seat to middle of track at most upright position with seat fully up off floor
25. Select "Coolant Fill/Drain" through Service UI
    Note

    Select 'Coolant System' to enter coolant circuit screen, Select 'Coolant Fill/Drain' and 'PROC_VCFRONT_X_START-THERMAL-FILL-DRAIN-COOLANT' window will appear, Select 'Run', Verify indicator displays green for Coolant readiness, Thermal Fill Drain routine has a 5 hour time limit
26. Position wheel chocks fore and aft of RH rear wheel

    

27. Run ODIN routine PROC_EPB_X_SERVICE-MODE-STARTvia Toolbox:(link)
28. Disconnect MV power. See Mid-Voltage Power (Disconnect and Connect) (Modify).
29. Fold up 2nd row 60 seat
    Note

    Pull tether to release then lift up until locked in place

    

30. Fold up 2nd row 40 seat
    Note

    Pull tether to release then lift up until locked in place

    

    

31. Release LH front seat belt from pretensioner
    Note

    Unlock linkage by rotating lock screw counterclockwise, audible click when horizontal, do not rotate clockwise to avoid damage

    

    

    

32. Disconnect LH front seat harness
    Note

    1x connector, 2 stage locking tab, Release yellow locking tab, then release black lever to disconnect

    

    

    

33. Remove LH front seat from vehicle
    Note

    Recommend assistance, Use caution to not damage other components, Lift seat off risers, Rotate sideways and remove out back door opening

    

    

    

    

34. Release RH front seat belt from pretensioner
    Note

    Unlock the linkage by rotating the lock screw counterclockwise A light audible click will be heard, and the screw should remain horizontal Do not rotate clockwise to avoid damage to the mechanism

    

    

    

35. Disconnect RH seat
    Note

    1x connector, 2 stage locking tab, Release yellow locking tab, then release black lever to disconnect

    

    

    

36. Remove RH front seat from vehicle
    Note

    Recommend assistance, Use caution to not damage other components, Lift seat off risers, Rotate sideways and remove out back door opening

    

    

    

    

37. Remove center console front panel
    Note

    10x clips

    

    

38. Remove front bolts securing center console to riser
    Note

    4x bolts, 10mm, 5 Nm

    

39. Disconnect center console harness connectors
    Note

    2x connectors

    

40. Remove center console back panel
    Note

    10x clips, 3x connectors, 3x harness clips

    

    

    

41. Remove rear bolts securing center console to riser
    Note

    2x bolts, 10mm, 5 Nm

    

42. Remove center console
    Note

    Lift up to release from riser and remove center console from rear right door opening

    

    

43. Remove RH mid A-pillar trim
    Note

    1x clip, 3x tabs, Release tabs then slightly bend live hinge and release clip

    

    

    

44. Remove RH lower A-pillar trim
    Note

    7x clips, 3x datums, 2x tabs, Release sill plate, Pull rearward then upward

    

    

    

45. Remove RH outboard riser bolt cover
    Note

    Lift from outer edge then pull away

    

    

    

46. Remove RH seat riser assembly from vehicle
    Note

    4x bolts, 13mm, 40 Nm, 3x clips, release cabin MV harness and 1x clip air duct from riser assembly

    

    

    

47. Remove LH mid A-pillar trim
    Note

    1x clip, 3x tabs, Release tabs then slightly bend live hinge and release clip

    

    

    

48. Remove LH lower A-pillar trim
    Note

    7x clips, 3x datums, 2x tabs, Release sill plate, Pull rearward then upward

    

    

    

49. Remove LH outboard riser bolt cover
    Note

    Lift from outer edge then pull away

    

    

    

50. Remove LH seat riser assembly from vehicle
    Note

    4x bolts, 13mm, 40 Nm, 3x clips, release cabin MV harness,6x clips If vehicle has cabin outlets release cabin HV outlet harness, and 1x clips release air duct from riser assembly

    

    

    

    

51. Remove footwell cover
    Note

    3x clips, 3x magnets, 1x bolt, 10mm, 3 Nm, Bolt is captive to tether

    

    

    

    

52. Remove LH front floor mat
53. Remove LH center floor rail
    Note

    4x clips, 3x datums, Pull upwards to release

    

    

54. Remove accelerator pedal side trim
    Note

    3x clips, Lift from forward edge then slide over accelerator pedal

    

    

    

55. Remove accelerator pedal
    Note

    2x nuts, 13mm, 10 Nm, 1x connector, Release locking tab

    

    

56. Remove LH front cabin carpet
    Note

    Plastic portions at rear of carpet need to clear risers, if needed break EPA at line to allow the corner to pass over the risers

    

    

    

    

    

57. Remove LH carpet support foam
    Note

    Lift up from rear edge

    

    

58. Remove LH front interior HV Battery mounting bolts
    Note

    3x bolts, 24mm, 160 Nm

    

59. Remove RH front floor mat
60. Remove RH center floor rail
    Note

    4x clips, 3x datums, Pull upwards to release

    

    

61. Remove center floor trim
    Note

    17x clips, Release upper section first

    

    

    

    

62. Remove RH front cabin carpet
    Note

    Plastic portions at rear of carpet need to clear risers

    

    

    

    

63. Remove RH carpet support foam
    Note

    Lift up from bottom edge

    

    

64. Remove RH interior front HV battery mounting bolts
    Note

    3x bolts, 24mm, 160 Nm

    

65. Remove 2nd row floor mat
66. Partially release LH lower C-pillar trim
    Note

    1x clip, 1x datum

    

    

67. Partially release RH lower C-pillar trim
    Note

    1x clip, 1x datum

    

    

68. Remove rear wall lower trim
    Note

    2x push clips, 4x clips, Remove outermost push clips, then pull straight forward to release inner clips

    

    

    

    

    

    

69. Remove rear carpet LH duct bezel
    Note

    4x clips

    

    

    

70. Remove rear carpet RH duct bezel
    Note

    4x clips

    

    

    

71. Remove LH lower B-pillar trim
    Note

    2x push clips, 11x clips, 4x datums, 4x seal retainers, 2x hooks, Release bottom rear section first

    

    

    

    

72. Remove rear carpet assembly
    Note

    4x clips, 17x stands, 6x datums, Release stands around LH and RH floor ducts then release stands at center console, Fold back carpet and stands from forward edge, Fold rear carpet and foam forwards then pull center of carpet and foam upwards to remove, Remove clips if they remain on pack side

    

    

    

    

    

73. Remove RH subwoofer
    Note

    1x connector, 2x bolts, 13mm, 8 Nm, Slide towards center of vehicle to release outer port from body

    

    

74. Remove RH rear interior HV battery mounting bolts
    Note

    4x bolts, 13mm, 60 Nm, Bolts on both sides of stanchion, Some vehicles may have a mix of 13mm and 15mm bolts

    

    

    

    

75. Remove LH subwoofer
    Note

    1x connector, 2x bolts, 13mm, 8 Nm, Slide towards RH of vehicle to release outer port from body, Release locking tab

    

    

76. Remove LH rear interior HV battery mounting bolts
    Note

    4x bolts, 13mm, 60 Nm, Bolts on both sides of stanchion, Some vehicles may have a mix of 13mm and 15mm bolts

    

77. Remove center floor upper bracket
    Note

    2x push clips, 2x edge clips, 2x retaining clips, Depress either side of retaining clip then push inward to release upper bracket from duct

    

    

    

    

    

    

78. Remove center floor lower support bracket
    Note

    4x clips

    

    

    

79. Remove center console riser duct
    Note

    2x clips, Maneuver forward to clear riser assembly

    

    

80. Remove floor jumper duct
    Note

    Push forward then lift and slide out

    

    

81. Remove 2nd row duct on rails
    Note

    Pull from the bottom to release

    

    

82. Release connectors from RCM
    Note

    2x connectors, Release red locking tabs first then depress connecter and slide forward

    

    

83. Remove RCM fasteners
    Note

    3x nuts, 10mm, 10 Nm, Discard fasteners after removal

    

84. Remove RCM from vehicle

    

    

85. Release LH MV controller dry side locking cover
    Note

    1x bolt, 8mm, 6 Nm, Do not remove locking cover, Loosen until bolt spins freely, Double check that bolt and locking cover are fully released before attempting to release any MV connectors, Plastic Locking CoverUse hand tools on any plastic locking covers, The locking cover may release crooked causing it to get stuck, secure bolt a few turns to loosen the tension then release bolt while assisting plastic locking cover by gently prying on the side that's stuck, Metal Locking CoverYou can use power tools, Quickly disconnecting locking cover helps connectors remove symmetrically, Video uses rear controller for demonstration purposes only

    

86. Release floor harness from LH MV controller
    Note

    1x connector, 1x clip, Depress tabs to release connector housing from locking cover

    

    

87. Release RH MV controller connector lower locking cover
    Note

    1x bolt, 8mm, 6 Nm, Do not remove locking covers, Loosen until bolts spins freely, Double check that bolts and locking covers are fully released before attempting to release any MV connectorsPlastic Locking Cover Use hand tools on any plastic locking covers, The locking covers may release crooked causing them to get stuck, secure bolts a few turns to loosen the tension then release bolts while assisting plastic locking covers by gently prying on the stuck sidesMetal Locking Cover You can use power tools, Quickly disconnecting locking covers helps connectors remove symmetrically

    

88. Release cabin floor and backbone harnesses from RH MV controller
    Note

    1x connector, 1x backbone cable, 2x edge clipsPull from edges of connector housing, Do not pull backbone cable, Avoid bending cable at a tight radiusDo not remove locking cover, Loosen until bolt spins freely, Double check that bolt and locking cover has fully released before attempting to release any MV connectors, Depress tabs on connector housing to releasePlastic Locking CoverUse hand tools on any plastic locking covers, The locking covers may release crooked causing them to get stuck, Thread bolt a few turns to avoid damage then gently pry stuck edges of locking coverMetal Locking CoverYou can use power tools, Quickly disconnecting locking covers helps connectors release evenly

    

    

    

89. Disconnect rear display connector from car computer
    Note

    1x connector

    

90. Remove cabin floor harness
    Note

    4x clips, 2x bolts, 10mm, 10 Nm

    

    

91. Remove RH 2nd row floor duct
    Note

    1x clip, Lift up then pull away to release duct from Y duct

    

    

92. Remove 2nd row floor Y-Duct
    Note

    1x clip, Release from passenger side duct then maneuver out of position

    

    

93. Release front section of backbone
    Note

    3x harness clips, Pass connector under cabin floor harness

    

94. Disconnect backbone harness from rear MV controller
    Note

    1x connector, 1x bolts, 8mm, 6 Nm, Do not remove locking cover, Loosen until bolt spins freely, Double check that bolt and locking cover has fully released before attempting to release any MV connectors, Depress tabs on connector housing to releasePlastic Locking CoverUse hand tools on any plastic locking covers, The locking covers may release crooked causing them to get stuck, Thread bolt a few turns to avoid damage then gently pry stuck edges of locking coverMetal Locking CoverYou can use power tools, Quickly disconnecting locking covers helps connectors release evenly

    

    

95. Remove backbone harness
    Note

    6x harness clips, Pull harness through to 2nd row then remove

    

    

96. Roll vehicle forward
    Note

    Remove fore wheel chock, Move vehicle to position necessary to place onto lift

    

    

    

97. Install Universal Lift Pad adapters
    Note

    4x Adapters, Remove original lift pads from lift arms then install respective adapter, Remove plugs from BIW holes, Align pins with lift point holes on body

    

    

    

98. Raise and support the vehicle. See Raise Vehicle - 2 Post Lift.
99. Remove the RH front and rear wheels. See Wheel Assembly (Remove and Install).
100. Verify operation of multimeter
     Note

     Set multimeter to DC voltage, Confirm multimeter is properly measuring voltage by testing MV battery, Touch lightly and do not damage terminals

     

     

101. Raise vehicle fully, lower lift onto locks
     Note

     Set vehicle to comfortable working height, Ensure an audible click of locks on both sides is heard before lowering, Vehicle may tilt to side if both locks are not engaged
102. Partially remove aft section of RH front wheel liner and secure
     Note

     2x 10mm bolt, 1x push clip Remove fasteners and clips then secure bottom aft portion of the wheel liner aside with bungee cord

     

     

103. Partially remove fore section of RH rear wheel liner and secure
     Note

     1x push clip 1x push nutRemove push clip and push nut and secure lower fore section wheel liner using bungee cord

     

     

104. Remove front aero shield stamping assembly and front fascia plastic skid plate fasteners
     Note

     17x bolts, 10mm, 6 Nm, Open bolt lids

     

     

     

105. Remove the skid plate stamping. See Skid Plate Stamping (Remove and Replace).
106. Remove the rear skid plate. See Skid Plate - Rear (Remove and Install).
107. Position coolant drain container underneath RH rear of HV battery

     

108. Disconnect RDU return hose from PT return hose
     Note

     1x spring clip, 1x clamp clip, Move wheel liner aside as needed, Plug coolant connections as needed, Hose connection near RH rear of HV battery

     

     

109. Disconnect coolant hoses from PCS coolant inlet and outlet couplers
     Note

     1x spring clip, Plug hoses and let coolant fully drain from PCS HV battery outlets before moving drain container, Hose connections located at RH rear of HV battery

     

     

110. Move coolant drain container to front right of HV battery

     

111. Disconnect PT supply and return hoses
     Note

     2x spring clips, Plug hoses, Hose connections located at RH front side of the vehicle

     

112. Disconnect battery coolant supply and return hoses
     Note

     2x spring clips, Hose connections located in the Front Center of the HV Battery, Use caution with pick near HV harness, Plug Hoses, Position coolant drain as needed

     

     

113. Remove coolant drain container from underneath vehicle
114. Remove all items from pockets and ensure not wearing metal items
     Note

     This includes: rings, watches, bracelets, necklaces, earrings, piercings, phones, badges, metal belt buckles, airpods and headphones
115. Inspect HV insulating gloves
     Note

     Check gloves for damage prior to use, Refer to service document TN-15-92-003, For information on inspecting HV gloves.

     

116. Put on HV insulating gloves and leather over gloves
     Note

     Use HV cut resistant insulated gloves or HV insulating gloves and leather over gloves, Perform a visual inspection of HV insulating gloves for any damage before putting on, Retest for leaks immediately following any incidents that can reasonably be suspected as causing damage to the HV insulating gloves, HV Insulating gloves must be worn any time a Hioki Tester or Hi-Pot Tester is used, Refer to service document TN-15-92-003 for PPE requirements depending on vehicle configurationhttps://service.tesla.com/en-US/documents

     

117. Verify no High Voltage on DC Link bus
     Note

     Verify with measurements performed at RDU HV harness connections to HV batteryMake sure to wear PPE (HV gloves, safety glasses) when working on high voltage componentVerify amp clamp meter is zeroed out before performing measurement, Measure single cable at rear drive unit HV harness, For Dual motor there is only one rear harness to measure, For AWD measure the RH rear harness, Verify ammeter is installed in correct direction. If current > 0.5A do not proceed with disconnecting HV connector. In this case, start HV disablement procedure again to make sure vehicle was properly shut down. Escalate for assistance as requiredIf current < 0.5A, Ok to disconnect and check voltage at HV plug on the battery side. For AWD disconnect LH rear drive unit harness for measurements, For Dual motor remove HV dummy plug for measurementsRelease locking tab and rotate the release lever up to disengage the connector, Release harness clip, Do not force the release lever up, Ensure the alignment tabs on the RDU header are not damagedMeasure B+ to Ground, B- to Ground, B+ to B-, If voltage is greater than 10V, Pack contactors are not open or welded, Stop work and reach out to Service Engineering

     

     

     

     

     

     

118. Release A/C compressor HV harness from HV battery
     Note

     1x locking connector, 4x clips, Pull down red locking tab and disengage the release lever, Do not force the release lever up, Number of connections may vary by vehicle configuration

     

     

     

119. Release RDU HV harness from HV battery
     Note

     1x connector, Release locking tab and rotate release lever up, Do not force release lever up, Ensure alignment tabs on header are not damaged, NOTE: During HV battery assembly replacement transfer HV battery dummy plugs to new HV battery pack assembly as needed

     

120. Release FDU HV harness from FDU
     Note

     1x connector, 1x bolt, 10mm, 10 Nm, Move harness clear of subframe

     

     

     

121. Remove leather over gloves and HV insulating gloves
     Note

     HV gloves should always be stored in the original packaging and inside a storage box or bag to prevent damage, Make sure that gloves are lying flat not bent or folded
122. Lower vehicle until tires are touching ground
     Note

     Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
123. Remove the bed floor assembly. See Bed Floor Assembly (Long Range) (Remove and Install).
124. Install ancillary access bench onto bed floor opening
     Note

     1x bench, Position above rear casting (Use step for non-premium bed floor procedures)

     

125. Remove the tonneau NVH barrier. See Tonneau NVH Barrier Assembly (Remove and Install).
126. Remove two rear tonneau square profile support braces
     Note

     8x screws, T30, 5 Nm, 2x support braces, Remove two square support braces that are closest to rear of vehicle, Remove bolts at each end of support braces, Slide braces off of mounting points on flat cassette assemblies, Braces slide off in same direction of fasteners, maneuver each brace out of bed opening (*Note: No part number provided for the screws, they come with the square profile brace)

     

     

127. Remove bolts securing HV battery to RUB
     Note

     4x bolts, 21mm, 115 Nm, Break free before using power tools, Tonneau slats must be closed or removed to access forward bolts, Shown without tonneau for clarity

     

     

     

128. Disconnect ancillary bay MV connector
     Note

     1x connector, Double locking, Release tab then pivot lever, Release second tab to disengage connector, Wait 1 second between locking tab release to discharge and prevent arcing

     

     

     

     

     

129. Remove all items from pockets and ensure not wearing metal items
     Note

     This includes: rings, watches, bracelets, necklaces, earrings, piercings, phones, badges, metal belt buckles, airpods and headphones
130. Put on HV insulating gloves and leather over gloves
     Note

     Use HV cut resistant insulated gloves or HV insulating gloves and leather over gloves, Perform a visual inspection of HV insulating gloves for any damage before putting on, Retest for leaks immediately following any incidents that can reasonably be suspected as causing damage to the HV insulating gloves, HV Insulating gloves must be worn any time a Hioki Tester or Hi-Pot Tester is used, Refer to service document TN-15-92-003 for PPE requirements depending on vehicle configuration

     

131. Remove bolt securing busbar HV connector lid
     Note

     1x bolt, EP10, 9 Nm

     

132. Remove bolts securing HV connector to DC FC header
     Note

     2x bolts, 10mm, 9 Nm

     

133. Release HV connector from DC FC header
     Note

     1x connector, Use inflatable airbag if needed to suspend busbar assembly above ancillary assembly

     

134. Support HV Busbar assembly
     Note

     1X Bungee, Suspend assembly to maintain clearance, wrap bungee around busbar assembly to achieve required cord length, Connect bungee to tie down hook on bed side

     

     

135. Disconnect bed outlet HV harness
     Note

     1x connector, Release red locking tab then slide open black lever to remove, NOTE: Transfer dummy plugs to new HV battery pack as needed.

     

136. Remove leather over gloves and HV insulating gloves
     Note

     HV gloves should always be stored in the original packaging and inside a storage box or bag to prevent damage, Make sure that gloves are lying flat not bent or folded
137. Raise vehicle fully
     Note

     Set to a comfortable working height, Lower to locks, Ensure locks engage on both sides to prevent tilting
138. Position battery table under vehicle
     Note

     Ensure table is level, center table to HV battery

     

139. Lower vehicle onto battery table
     Note

     Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered, Lower until HV battery surface touches table evenly, *Do not lower full weight of vehicle onto table, Recommend assistance, Align table to vehicle and raise casters to level table if necessary

     

     

140. Remove front exterior HV Battery mounting bolts and ground strap
     Note

     6x bolts, 18mm, 115 Nm, 1x bolt, 10mm, 10 Nm, Ensure ground strap is clear of battery

     

     

141. Remove side exterior HV battery mounting bolts from LH and RH side
     Note

     16x bolts, 15mm, 60 Nm

     

142. Raise vehicle away from HV battery
     Note

     Raise vehicle fully off of HV battery and lower lift onto locks, Ensure an audible click of locks on both sides is heard before lowering, Vehicle may tilt to the side if both locks are not engaged, Ensure no coolant hoses harnesses or brake lines are caught while lifting, If lift is shorter then remove rear wheels as needed

     

     

143. Remove HV battery from underneath vehicle
     Note

     Recommend assistance

     

144. Remove FDU HV harness
     Note

     12x bolts, 10mm, 11 Nm, NOTE: FDU HV harness on new HV battery may not be necessary for vehicle configuration (i.e. RWD) Transfer to new HV battery pack as needed

     

     

     

145. Remove powertrain hose bundle
     Note

     1x spring clip, 6x clips, Release hose from PCS fitting

     

     

     

146. Obtain HV battery vitals screenshot
     Note

     Reference steps in 16018725
147. Remove all items from pockets and ensure not wearing metal items
     Note

     This includes: rings, watches, bracelets, necklaces, earrings, piercings, phones, badges, metal belt buckles, airpods and headphones
148. Put on HV insulating gloves and leather over gloves
     Note

     Use HV cut resistant insulated gloves or HV insulating gloves and leather over gloves, Perform a visual inspection of HV insulating gloves for any damage before putting on, Retest for leaks immediately following any incidents that can reasonably be suspected as causing damage to the HV insulating gloves, HV Insulating gloves must be worn any time a Hioki Tester or Hi-Pot Tester is used, Refer to service document TN-15-92-003 for PPE requirements depending on vehicle configuration

     

149. Remove pyro access cover
     Note

     4x bolts, E-Torx 5 lobe, 10 Nm, NOTE: Transfer pyro access cover to new HV battery assembly as needed during HV battery replacement

     

     

150. Remove primary and secondary pyro fuses
     Note

     4x bolts, 13mm, 5 Nm + 60 Degrees, Support each pyro fuse while removing bolts

     

     

151. Install pyro fuse access cover
     Note

     4x bolts, E-Torx 5 lobe, 10 Nm, Ensure seal is fully seated and undamaged

     

     

152. Remove leather over gloves and HV insulating gloves
     Note

     HV gloves should always be stored in the original packaging and inside a storage box or bag to prevent damage, Make sure that gloves are lying flat not bent or folded
153. Apply backbone harness abrasion protection
     Note

     6x abrasion tape strips, Apply narrow patch to forwardmost position between should bracket ribs, Refer to image for clarity, Skip step if abrasion protection already present and installed correctly, Wide patch dimensions: 50mm wide, 150mm long, Narrow patch dimensions: 25.4mm wide, 235mm long

     

154. Install powertrain hose bundle
     Note

     1x spring clip, 6x clips, Perform a push-pull-push test to ensure hose is fully seated

     

     

     

155. Install FDU HV harness
     Note

     12x bolts, 10mm, 11 Nm

     

     

     

156. Position HV battery beneath vehicle
     Note

     Recommend assistance

     

157. Install HV battery alignment rods into front casting
     Note

     4x alignment rods, Hand tight, Install 2x larger rods onto front casting, Install 2x smaller rods onto seat stancion mounting holes on pack, New battery packs may not yet have threads in the required holes. Suggest installing bolt to create threads prior to rod installation, It is not recommended to use any holes other than instructed

     

     

     

158. Lower vehicle onto HV battery
     Note

     Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered, Align the pack to the vehicle using the alignment rods, Ensure no coolant hoses, harnesses, or brake lines are caught while lowering, Recommend assistance to ensure good alignment whilst lowering

     

     

159. Install side exterior HV battery mounting bolts onto LH and RH side
     Note

     16x bolts, 15mm, 60 Nm

     

160. Remove HV battery alignment rods from front casting
     Note

     2x alignment rods

     

161. Install front exterior HV Battery mounting bolts and ground strap
     Note

     6x bolts, 18mm, 115 Nm, 1x bolt, 10mm, 10 Nm

     

     

162. Raise vehicle away from battery table
     Note

     Set to a comfortable working height, Ensure lift is lowered onto a lock

     

     

     

163. Remove battery table from under vehicle

     

164. Remove all items from pockets and ensure not wearing metal items
     Note

     This includes: rings, watches, bracelets, necklaces, earrings, piercings, phones, badges, metal belt buckles, airpods and headphones
165. Put on HV insulating gloves and leather over gloves
     Note

     Use HV cut resistant insulated gloves or HV insulating gloves and leather over gloves, Perform a visual inspection of HV insulating gloves for any damage before putting on, Retest for leaks immediately following any incidents that can reasonably be suspected as causing damage to the HV insulating gloves, HV Insulating gloves must be worn any time a Hioki Tester or Hi-Pot Tester is used, Refer to service document TN-15-92-003 for PPE requirements depending on vehicle configuration

     

166. Connect FDU HV harness to front Drive Unit
     Note

     1x connector, 1x bolt, 10mm, 10 Nm, Ensure locking tab engages

     

     

     

167. Secure RDU HV harness to HV battery
     Note

     1x connector, 1x harness clip, Ensure locking tab is engaged, NOTE: During HV battery assembly replacement transfer HV battery dummy plugs to new HV battery pack assembly as needed

     

168. Secure A/C compressor HV harness onto battery
     Note

     1x locking connector, 4x clips, Engage locking tab, Do not force lever up, Number of connections may vary by vehicle configuration

     

     

     

     

169. Remove leather over gloves and HV insulating gloves
     Note

     HV gloves should always be stored in the original packaging and inside a storage box or bag to prevent damage, Make sure that gloves are lying flat not bent or folded
170. Move coolant drain container to front right of HV battery

     

171. Connect battery supply and return coolant hoses
     Note

     2x edge clips, 2x spring clips, Remove plugs, Secure edge clips to casting, Perform a push-pull-push test to ensure hose is engaged, Hose connections located at center of battery front edge, Reposition coolant drain container as needed

     

     

172. Connect PT supply and return hoses
     Note

     2x spring clips, Remove plugs, Perform a push-pull-push test to ensure hose is engaged, Hose connections located at RH front of HV Battery

     

173. Position coolant drain container underneath RH rear of HV battery

     

174. Connect RDU supply hose to HV Battery
     Note

     1x spring clip, Remove coolant plugs, Perform a push-pull-push test to ensure hose is engaged, Hose connections located at RH rear of HV Battery

     

175. Connect RDU return hose to PT return hose
     Note

     1x spring clip, Remove coolant plugs, Pull back wheel liner as required, Perform a push-pull-push test to ensure hose is engaged, Hose connection located at RH rear of HV Battery

     

     

176. Remove coolant drain container from underneath vehicle
177. Install the rear skid plate. See Skid Plate - Rear (Remove and Install).
178. Install the skid plate stamping. See Skid Plate Stamping (Remove and Replace).
179. Install front aero shield stamping assembly and front fascia plastic skid plate fasteners
     Note

     17x bolts, 10mm, 6 Nm, Apply Loctite 222 to aero shield fasteners, Close bolt lids

     

     

180. Install RH rear wheel liner
     Note

     1x push clip 1x push nutRemove bungee cord, install push clip and push nut

     

     

181. Install RH front wheel liner
     Note

     2x 10mm bolt, 1x push clip Remove bungee cord and install fasteners and clips

     

     

182. Install the RH front and rear wheels. See Wheel Assembly (Remove and Install).
183. Position wheel chocks fore and aft of RH rear wheel

     

184. Remove all items from pockets and ensure not wearing metal items
     Note

     This includes: rings, watches, bracelets, necklaces, earrings, piercings, phones, badges, metal belt buckles, airpods and headphones
185. Put on HV insulating gloves and leather over gloves

     

186. Connect bed outlet HV harness
     Note

     1x connector, Slide black lever to engage then push in red locking tab, NOTE: Transfer dummy plugs to new HV battery pack as needed.

     

187. Clean contact surface of HV DC inlet posts
     Note

     Allow 1 minute dry time after removing Penetrox, New busbar comes with Penetrox applied to HV connector, Clean residual penetrox

     

188. 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

     

189. Apply Penetrox onto HV DC Inlet posts
     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

     

190. Install busbar onto HV header and install bolts
     Note

     2x bolts, 10mm, 9 Nm

     

     

191. 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 0.005 mΩ (5 μΩ) and 0.195 mΩ (195 μΩ).If resistance is consistently greater than 0.195 mΩ (195 μΩ) remove bolt clean busbar and bolt with ISO alcohol reinstall bolt and remeasure. If resistance still too high stop work and escalate Toolbox session.If resistance is lower than 0.005 mΩ (5 μΩ), reposition the probes and measure again.If resistance is repeatedly between 0.005 mΩ (5 μΩ) and 0.195 mΩ (195 μΩ) Hioki test passed, proceed to next step

     

     

     

192. Install bolt securing busbar HV connector lid
     Note

     1x bolt, EP10, 9 Nm

     

193. Remove leather over gloves and HV insulating gloves
     Note

     HV gloves should always be stored in the original packaging and inside a storage box or bag to prevent damage, Make sure that gloves are lying flat not bent or folded
194. Connect ancillary bay MV connector
     Note

     1x connector, double locking, Rotate lever into 2nd lock, Perform a pull test to ensure connector engaged correctly

     

     

     

     

     

195. Install bolts securing HV battery to RUB
     Note

     4x bolts, 21mm, 115 Nm, Tonneau must be closed or removed to access forward bolts, Shown without tonneau for clarity

     

     

196. Install two rear tonneau square profile support braces
     Note

     8x screws, T30, 5 Nm, Install two square support braces, The tope and bottom braces that are closest to rear of vehicle, Slide notches at each of support brace to mounting points on flat cassette assemblies, Square supports install in the same direction of the fasteners

     

     

197. Install the tonneau NVH barrier. See Tonneau NVH Barrier Assembly (Remove and Install).
198. Remove ancillary access bench from bed floor opening
     Note

     1x bench (Use this step for non-premium bed floor procedures)

     

199. Install the bed floor assembly. See Bed Floor Assembly (Long Range) (Remove and Install).
200. Remove the vehicle from the lift. See Raise Vehicle - 2 Post Lift.
201. Roll vehicle rearward
     Note

     Position vehicle so front doors can be fully opened, Chock wheels once vehicle is in desired position

     

     

     

202. Install backbone harness
     Note

     6x harness clips, Push harness through to 1st row

     

     

203. Inspect backbone harness for misalignment near rear ribs
     Note

     Ensure cable is lying flat without twist, Ensure cable is secured correctly to rib, Apply surface protection at seam of rearmost rib under backbone cable if missing

     

     

     

204. Inspect for presence of backbone harness guide at front casting
     Note

     Ensure backbone harness guide is installed

     

205. Secure front section of backbone
     Note

     3x clips, Route connector under cabin floor harness

     

206. Connect backbone harness to rear MV controller
     Note

     1x connector, 1x bolt, 8mm, 6 Nm, Push backbone connector housing into plastic locking cover, Ensure connector housing is secured to locking frame with a push-pull-push test, Ensure connectors are aligned before securing bracket, Secure locking cover bolt by hand initially to prevent thread stripping Plastic Locking Cover Use hand tools on any plastic locking covers, The locking cover may secure crooked causing it to get stuck, release bolt a few turns to loosen the tension then secure bolt while assist plastic locking cover by gently pushing on the side that's stuck, Push connectors too while driving the locking cover bolt to ensure correct seating Metal Locking Cover You can use power tools, Slowly drive locking cover, Ensure locking cover and bolt are seated fully

     

     

207. Install 2nd row floor Y-Duct
     Note

     1x clip, Maneuver into position then secure to passenger side duct

     

     

208. Install RH 2nd row floor duct
     Note

     1x clip, Align floor duct with Y duct then push inward to engage

     

209. Install cabin floor harness
     Note

     (USE THIS STEP FOR HV BATTERY REPLACEMENT PROCEDURES WHEN RCM AND SEAT RISERS ARE NOT INSTALLED) 4x clips, 2x bolts, 10mm, 10 Nm, Harness clips to HV Battery top surface near area HV battery meets front vehicle body, Bolts secure two harness ground points to top of HV Battery

     

     

210. Connect rear display connector to car computer
     Note

     1x connector

     

211. Secure cabin floor and backbone harnesses onto RH MV controller
     Note

     1x connector, 1x backbone cable, 2x edge clips, 3x harness clips, Push from edges of connector housing, Avoid bending ribbon cable at a tight radius

     

     

     

212. Secure RH MV controller connector locking cover
     Note

     1x bolt, 8mm, 6 Nm, Ensure connector housing is secured to locking frame with a push-pull-push test, Ensure connectors are aligned before securing bracket, Secure locking cover bolt by hand initially to prevent thread stripping Plastic Locking Cover Use hand tools on any plastic locking covers, The locking cover may secure crooked causing it to get stuck, release bolt a few turns to loosen the tension then secure bolt while assist plastic locking cover by gently pushing on the side that's stuck, Push connectors while driving the locking cover bolt to ensure correct seating Metal Locking Cover You can use power tools, Slowly drive locking cover, Ensure locking cover and bolt

     

213. Secure floor harness onto LH MV controller
     Note

     1x connector, 1x clip, Secure in locking cover

     

     

214. Secure left MV controller connector locking frame
     Note

     1x bolt, 8mm, 6 Nm, Ensure connectors are aligned before tightening center bolt

     

215. Position RCM for installation

     

216. Install RCM to HV battery assembly
     Note

     3x nuts, 10mm, 10 Nm, Install new nuts

     

217. Connect floor harness connectors to RCM
     Note

     2x connectors, Engage locking tabs

     

     

218. Install 2nd row dual duct on rails
     Note

     Maneuver as needed through foam insert

     

219. Install floor jumper duct
     Note

     2x clips

     

     

220. Install center console riser duct
     Note

     2x clips, Install from front of riser assembly, Replace any missing or damaged clips

     

     

221. Install center floor lower support bracket
     Note

     4x clips, Replace any missing or damaged clips

     

     

     

222. Install center floor upper bracket
     Note

     2x push clips, 4x clips

     

     

     

     

     

     

223. Remove HV battery alignment rods from stancion mounting holes on pack
     Note

     2x alignment rods

     

224. Install LH rear interior HV battery mounting bolts
     Note

     4x bolts, 13mm, 60 Nm, Bolts on both sides of stanchion, Some vehicles may have a mix of 13mm and 15mm bolts

     

225. Install LH subwoofer
     Note

     1x connector, 2x bolts, 13mm, 8 Nm, Slide towards LH of vehicle to secure outer port to body, Engage locking tab

     

     

226. Install RH rear interior HV battery mounting bolts
     Note

     4x bolts, 13mm, 60 Nm, Bolts on both sides of stanchion, Some vehicles may have a mix of 13mm and 15mm bolts

     

     

     

     

227. Install RH subwoofer
     Note

     1x connector, 2x bolts, 13mm, 8 Nm, Slide towards outside of vehicle to secure port

     

     

228. Install rear carpet assembly
     Note

     4x clips, 6x datums, Secure center foams and datums, Secure stands at center console then secure stands around LH and RH floor ducts, Fully tuck carpet under risers and trim, Replace any missing or damaged clips

     

     

     

     

     

229. Install LH lower B-pillar trim
     Note

     2x push clips, 11x clips, 4x datums, 4x seal retainers, 2x hooks, Secure top hooks first

     

     

     

     

230. Install rear carpet RH duct bezel
     Note

     4x clips, Replace any missing or damaged clips

     

     

     

231. Install rear carpet LH duct bezel
     Note

     4x clips, Replace any missing or damaged clips

     

     

     

232. Install rear wall lower trim
     Note

     2x push clips, 4x clips

     

     

     

     

     

     

233. Secure RH lower C-pillar trim
     Note

     1x clip, 1x datum

     

234. Secure LH lower C-pillar trim
     Note

     1x clip, 1x datum

     

235. Install 2nd row floor mat
236. Install RH interior front HV battery mounting bolts
     Note

     3x bolts, 24mm, 160 Nm

     

237. Install RH carpet support foam
     Note

     Seat at rear edge

     

238. Install RH front cabin carpet
     Note

     Plastic portions at rear of carpet need to clear risers

     

     

     

     

239. Install center floor trim
     Note

     17x clips, Replace any missing or damaged clips, Install lower section first

     

     

     

     

240. Install RH center floor rail
     Note

     4x clips, 3x datums

     

     

241. Install RH front floor mat
242. Install LH front interior HV Battery mounting bolts
     Note

     3x bolts, 24mm, 160 Nm

     

243. Install LH carpet support foam
     Note

     Seat at rear edge

     

244. Install LH front cabin carpet
     Note

     Plastic portions at rear of carpet need to clear risers

     

     

     

     

     

245. Install accelerator pedal
     Note

     2x nuts, 13mm, 10 Nm, 1x connector, Secure locking tab

     

     

246. Install accelerator pedal side trim
     Note

     3x clips, Replace any missing or damaged clips

     

     

     

247. Install LH center floor rail
     Note

     4x clips, 3x datums

     

     

248. Install LH front floor mat
249. Install footwell cover
     Note

     3x clips, 3x magnets, 1x bolt, 10mm, 3 Nm, Bolt is captive to tether, Replace any missing or damaged clips or magnets

     

     

     

     

250. Install LH seat riser assembly
     Note

     4x bolts, 13mm, 40 Nm, 8x clips, release cabin MV harness, If vehicle has cabin outlets attach cabin HV outlet harness to seat riser, Attach air duct to seat riser

     

     

     

     

251. Install LH outboard riser bolt cover

     

     

     

252. Install LH Lower A-pillar trim
     Note

     7x clips, 3x datums, 2x tabs, Replace any missing or damaged clips

     

     

     

253. Install LH mid A-pillar trim
     Note

     1x clip, 3x tabs, Replace any missing or damaged clips

     

     

     

254. Install RH seat riser assembly
     Note

     4x bolts, 13mm, 40 Nm, 3x clips attach cabin MV harness,6x clips attach cabin HV outlet harness, and attach1x clips release air duct onto riser assembly

     

     

255. Install RH outboard riser bolt cover

     

     

     

256. Install RH lower A-pillar trim
     Note

     7x clips, 3x datums, 2x tabs

     

     

     

257. Install RH mid A-pillar trim
     Note

     1x clip, 3x tabs, Replace any missing or damaged clips

     

     

     

258. Position center console in vehicle
     Note

     Lower onto riser

     

     

259. Install rear bolts securing center console to riser
     Note

     2x bolts, 10mm, 5 Nm

     

260. Install center console rear panel
     Note

     10x clips, 3x connectors, 3x harness clips, Replace any missing or damaged clips

     

     

     

261. Connect center console harness connectors
     Note

     2x connectorsConnectors located toward the bottom on the front of the center console

     

262. Install front bolts securing center console to riser
     Note

     4x bolts, 10mm, 5 Nm

     

263. Install center console front panel
     Note

     10x clips, Replace any missing or damage clips

     

     

264. Position RH front seat into vehicle
     Note

     Recommend Assistance and position seat through rear door, Be cautious not to damage surrounding components while lifting the seat into the vehicle, Seat bolts will be installed on a later step

     

     

     

265. Connect RH front seat harness
     Note

     1x connector, 2 stage locking tabs, Make connection and engage black lever, then engage yellow locking tab

     

     

     

266. Secure RH front seat belt to pretensioner
     Note

     Ensure the lock screw is in the horizonal position. If it is not, unlock it by following the linkage removal instructions.Slide the linkage onto the pretensioner cable, an audible click will be heard, and the screw should rotate to the locked position. Verify there are no twists in the webbing from the upper trim to the pretensioner. Perform a firm pull test with at least 15 pounds of force.

     

     

     

267. Position LH front seat into vehicle
     Note

     Recommend assistance and position seat through rear seat, Be cautious not to damage surrounding components while lifting the seat into the vehicle, Seat bolts will be installed on a later step

     

     

     

268. Connect LH front seat harness
     Note

     1x connector, 2 stage locking tabs, Make connection and engage black lever, then engage yellow locking tab

     

     

     

269. Secure LH front seat belt to pretensioner
     Note

     Ensure lock screw is in horizontal position, slide linkage onto pretensioner cable, audible click when screw rotates to locked position, verify no twists in webbing, perform firm pull test with 15 pounds of force

     

     

     

270. Fold down 2nd row 40 seat
     Note

     Pull tether to release then pivot down until locked in place

     

     

271. Fold down 2nd row 60 seat
     Note

     Pull tether to release then pivot down until locked in place

     

     

272. Perform cooling system vacuum refill. See Cooling System (Vacuum Refill).
273. Reconnect MV power. See Mid-Voltage Power (Disconnect and Connect) (Modify).
274. Secure MV battery maintainer and support vehicle
     Note

     1x cover, Secure MV maintainer but leave the Li-ion battery connected, Secure positive terminal to jump post, Secure negative terminal to bolt located between brake fluid reservoir and front trunk, Connect maintainer to power supply, DO NOT allow positive cable to make contact with other metal components, Prevent shorting the cables,Do not have a MV maintainer and the Li-ion battery simultaneously connected for any extended period of time

     

     

     

     

275. Move RH front seat backward
276. Install bolts securing RH front seat front tracks to vehicle
     Note

     2x patch bolts, T45P, 34 Nm, Install new bolts

     

277. Move RH front seat forward
278. Install bolts securing RH front seat rear tracks to vehicle
     Note

     2x patch bolts, T45P, 34 Nm, Install new bolts

     

279. Move LH front seat backward
280. Install bolts securing both LH front seat front tracks to vehicle
     Note

     2x patch bolts, T45P, 34 Nm, Install new bolts

     

281. Move LH front seat forward
282. Install bolts securing LH front seat rear tracks to vehicle
     Note

     2x patch bolts, T45P, 34 Nm, Install new bolts

     

283. Hold brake pedal and select park on UI to disable EPB service mode

     

284. Remove wheel chocks from RH rear wheel
     Note

     Confirm the truck is in Park and does not roll, then remove the fore and aft chocks from the RH rear wheel.

     

285. Remove MV battery maintainer
     Note

     1x cover, Unplug the maintainer first, then remove positive and negative leads from jump posts, Re-secure any jump post covers

     

     

     

286. Select 'High Voltage Battery Replacement Routine'
     Note

     Lightning Bolt Icon > High Voltage > Procedures > High Voltage Battery Replacement > High Voltage Battery Replacement Routine
287. Run ODIN routine PROC_EGGRIGHT3_X_THERMAL-FILL-DRAIN-STOPvia Service Mode:
     • Thermal ➜ Actions ➜ Stop Thermal Fill/Drain
     • Thermal ➜ Coolant System ➜ Stop Coolant Fill/Drain
     • Thermal ➜ Refrigerant System ➜ Stop Refrigerant Fill/Drain
     via Service Mode Plus:
     • Drive Inverter ➜ Front Drive Inverter Replacement ➜ Stop Fluid Fill/Drain
     • Drive Inverter ➜ Rear Drive Inverter Replacement ➜ Stop Fluid Fill/Drain
     • Drive Inverter ➜ Rear Left Drive Inverter Replacement ➜ Stop Fluid Fill/Drain
     • Drive Inverter ➜ Rear Right Drive Inverter Replacement ➜ Stop Fluid Fill/Drain
     • Drive Unit ➜ Front Drive Unit Replacement ➜ Stop Coolant Fill/Drain
     • Drive Unit ➜ Rear Drive Unit Replacement ➜ Stop Coolant Fill/Drain
     via Toolbox:(link)
288. Select "Start Coolant Air Purge" using the UI
     Note

     Touch time only, wait until coolant pumps stop running (audible noise), Routine Passed will appear, but pumps will run for 10 minutes, If you start next another routine during this time it will fail, Make sure vehicle is not in "Drive", Routine is still running despite the completed message, Speeds can be monitored in garage under PT Thermal tab, Idle speed = ~1500 RPM, Test will vary speeds from 3500-6500 RPM and actuate valves between SERIES and PARALLEL, Putting vehicle into "Drive" will stop this routine, If speeds hover at 7000 RPM, this indicates the pumps are air locked, perform a vacuum fill, Continue to add coolant and purge until the coolant level reaches between the NOM and MAX Lines on the bottle

     

     

     

289. Inspect coolant level and top off as necessary
     Note

     Ensure the fluid level is at the Max line, Top off fluid as required

     

290. Install coolant bottle cap

     

291. Install the RH rear rocker step reinforcement. See Rocker Step Reinforcement - Rear - LH (Remove and Install)
292. Install the RH front rocker step reinforcement. See Rocker Step Reinforcement - Front - LH (Remove and Install).
293. Install the RH rocker panel assembly. See Rocker Panel Assembly - LH (Remove and Install).
294. Install the LH rear rocker step reinforcement. See Rocker Step Reinforcement - Rear - LH (Remove and Install)
295. Install the LH front rocker step reinforcement. See Rocker Step Reinforcement - Front - LH (Remove and Install).
296. Install the LH rocker panel assembly. See Rocker Panel Assembly - LH (Remove and Install).
297. Perform Thermal Performance Test through the UI
     Note

     Select Thermal > Actions > Test Thermal Performance, click Run, close once routine is completed

     

     

     

     

298. Install the tonneau slats. See Slat System - Tonneau (Remove and Install).
299. Run ODIN routine PROC_EGGREAR1_TONNEAU-CALIBRATEvia Service Mode:Closures ➜ Tonneau ➜ Calibrate Tonneauvia Toolbox:(link)
300. Run ODIN routine PROC_RCM_X_SERVICE-TASKSvia Service Mode Plus:Safety & Restraints ➜ Safety Testing ➜ RCM Service Tasksvia Toolbox:(link)
301. Run ODIN routine PROC_ICE_X_EXIT-SERVICE-MODEvia Toolbox:(link)
302. Close tonneau cover
303. Install the rear underhood apron. See Underhood Apron - Rear (Remove and Install).
304. Raise all the windows and close all the doors.