HV Battery (Standard) (Remove and Install)

Open all four doors

Note

Push pillar door triggers to release

Lower all four windows

Manually latch all doors to prevent lockout

Note

Engage latch with screwdriver

Run ODIN routine PROC_ICE_X_ENTER-SERVICE-MODEvia Toolbox:(link)

Unlock vehicle gateway

Note

After vehicle has been put into "Service Mode", place keycard on center console to turn on drive rails, hold down the brake pedal, while keep pressing right hand signal button simultaneously for at least 10 seconds, "GTW UNLOCKING" should pop up on the UI right next to the VIN during these 10 seconds, once gateway is unlocked "GTW UNLOCKED 5400" will be displayed on the UI next to the VIN, the gateway will remain unlocked for 90 minutes, follow steps on Toolbox article #5582900 for any additional information

Run ODIN routine PROC_RCM_DISARMvia Service Mode Plus:

Safety & Restraints ➜ Airbags ➜ Disarm RCM
Safety & Restraints ➜ Seats ➜ Disarm RCM

via Toolbox:(link)

Open tailgate

Note

Press button to release, Use manual release as necessary

Open tonneau cover

Note

Press forward arrow on LH bed rail

Release LH sail applique

Note

6x tabs, Release rear portion of LH sail applique and support with inflatable airbag

Remove LH tonneau water management seal

Note

1x clip, Pull away from rail to release from groove

Release LH rear lamp closeout applique

Note

2x clips

Remove LH tonneau hard stop

Note

3x bolts, 10mm, 9 Nm(*Could not locate part number in catalog)

Remove LH tonneau slip datum bracket

Note

(*Could not locate part number in catalog)

Remove LH tailgate bumpstop

Note

1x datum, Rotate and release inboard

Remove RH sail applique

Note

6x tabs, Release rear portion of RH sail applique and support with inflatable airbag

Remove RH tonneau water management seal

Note

1x clip, Pull away from rail to release from groove

Release RH rear lamp closeout applique

Note

2x clips, 2x datums

Remove RH tonneau hard stop

Note

3x bolts, 10mm, 9 Nm(*Could not locate part number in catalog)

Remove RH tonneau slip datum bracket

Note

(*Could not locate part number in catalog)

Remove RH tailgate bumpstop

Note

1x datum, Rotate and release

Install tonneau transfer frame onto powertrain table

Note

4x bolts, 4x nuts, 1x Frame (*Tooling needed to tighten fasteners to lift table can vary depending on bolts used in Service)

Position tonneau transfer frame onto tonneau bed rails

Note

Connect air supply, Raise and adjust angle on powertrain table as needed

Align and secure tonneau transfer frame onto tonneau bed rails

Note

2x pins, Insert pin on each side once aligned

Run ODIN routine PROC_EGGREAR1_TONNEAU-CALIBRATEvia Service Mode:Closures ➜ Tonneau ➜ Calibrate Tonneauvia Toolbox:(link)

Release tonneau chain from motors

Note

Recommend assistance, Press close button until both motors have audibly released all links

Manually guide remaining tonneau slats and chain out of bed rails

Note

Recommend assistance, 2x pins, Remove pins then move powertrain table away from vehicle and guide slats out

Move vehicle onto lift

Note

Ensure positioning allows rear doors to open, NOTE: If burning odors, popping sounds, flames, or smoke is seen at any time, halt this process and call the fire department immediately! Begin evacuation if vehicle is in the shop.

Move LH front seat backward

Remove bolts securing front of LH front seat tracks to risers

Note

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

Raise and move LH front seat forward

Remove bolts securing rear of LH front seat tracks to floor

Note

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

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

Move RH front seat backward

Remove bolts securing front of RH front seat tracks to risers

Note

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

Move RH front seat forward

Remove bolts securing rear of RH front seat tracks to the floor panel

Note

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

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

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 50 minute time limit

Open powered front trunk

Note

Via exterior switch or UI

Remove rear underhood apron

Note

9x clips

Power off vehicle from center display

Note

Verify EPBs are engaged, Select charge port icon to ensure drive state is disengaged then power down vehicle via Controls > Safety > Power Off

Disconnect first responder loop and MV battery connector

Note

2x connectors, Release locking tab then disconnect FRL connector, Slide eCPA to left then lift lever to release MV battery connector, Early production trucks may have black FRL connector, Release eCPA by pushing down to unlock and slide red locking tab, Wait 2 minutes for electrical circuits to discharge before disconnecting modules

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

Raise vehicle fully and 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 the side if both locks are not engaged

Remove aero shield fasteners

Note

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

Remove front skid plate

Note

8x nuts, 15mm, 50 Nm, 2x bolts, 11mm, 50 Nm

Remove mid-aero shield

Note

6x clips, 3x bolts, 15mm, 42 Nm, 5x bolts, 13mm, 28 Nm, 2x bolts, 10mm, 6 Nm(*15mm & 10mm bolts not shown in catalog, feedback sent)

Remove all items from pockets and ensure not wearing metal items

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.

Put on HV insulating gloves and leather over gloves

Note

Use HV cut resistant insulated gloves or HV insulating gloves and leather over 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 R5 for PPE requirements depending on vehicle configuration.

Verify no HV - Install amp clamp to RDU HV harness

Note

Verify meter is zeroed out before performing measurement, Measure single cable. Verify ammeter is installed in correct direction. If current > 0.5A do not proceed with disconnecting HV connector. In this case, start vehicle electrical isolation again to make sure that all 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.Release 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 damagedMake sure to wear PPE (HV gloves, safety glasses) when working on high voltage component, Measure 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

Remove leather over gloves and HV insulating gloves

Disconnect EPB harness connector from LH rear brake caliper

Note

1x connector, Release locking tab

Release the RH rear parking brake with EPB release tool

Note

1x connector, Connect EPB release tool to brake caliper then press release button to disengage park brake, Disconnect EPB release tool once complete

Connect LH rear EPB harness

Note

1x connector, Engage locking tab

Disconnect RH rear EPB harness

Note

1x connector, Release locking tab

Release the RH rear parking brake with EPB release tool

Note

1x connector, Connect EPB release tool to brake caliper then press release button to disengage park brake, Disconnect EPB release tool once complete

Connect RH rear EPB harness

Note

1x connector, Engage locking tab

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

Position wheel chocks fore and aft of RH rear wheel

Remove vehicle from lift

Note

Lower rack arms fully and remove them from under vehicle,

Roll vehicle rearward

Note

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

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

Disconnect LH front seat harness

Note

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

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

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

Disconnect RH seat

Note

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

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

Remove center console front panel

Note

10x clips

Remove front bolts securing center console to riser

Note

4x bolts, 10mm, 5 Nm

Disconnect center console harness connectors

Note

2x connectors

Remove center console back panel

Note

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

Remove rear bolts securing center console to riser

Note

2x bolts, 10mm, 5 Nm

Remove center console

Note

Lift up to release from riser

Remove RH outboard riser bolt cover

Note

Lift from outer edge then pull away

Remove RH seat riser assembly from vehicle

Note

4x bolts, 13mm, 40 Nm, 2x clips, release cabin MV harness and air duct from riser assembly

Remove LH outboard riser bolt cover

Note

Lift from outer edge then pull away

Remove LH seat riser assembly from vehicle

Note

4x bolts, 13mm, 40 Nm, 2x clips, release cabin MV harness and air duct from riser assembly

Remove footwell cover

Note

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

Remove LH front floor mat

Remove LH mid A-pillar trim

Note

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

Remove LH lower A-pillar trim

Note

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

Remove LH center floor rail

Note

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

Remove accelerator pedal side trim

Note

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

Remove accelerator pedal

Note

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

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

Remove LH carpet support foam

Note

Lift up from rear edge

Remove LH front interior HV Battery mounting bolts

Note

3x bolts, 24mm, 160 Nm

Remove RH front floor mat

Remove RH mid A-pillar trim

Note

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

Remove RH lower A-pillar trim

Note

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

Remove RH center floor rail

Note

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

Remove center floor trim

Note

17x clips, Release upper section first

Remove RH front cabin carpet

Note

Plastic portions at rear of carpet need to clear risers

Remove RH carpet support foam

Note

Lift up from rear edge

Remove RH interior front HV battery mounting bolts

Note

3x bolts, 24mm, 160 Nm

Fold up 2nd row 60 seat

Note

Pull tether to release then lift up until locked in place

Remove 2nd row floor mat

Partially release LH lower C-pillar trim

Note

1x clip, 1x datum

Fold up 2nd row 40 seat

Note

Pull tether to release then lift up until locked in place

Partially release RH lower C-pillar trim

Note

1x clip, 1x datum

Remove rear wall lower trim

Note

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

Remove LH rear carpet duct bezel

Note

4x clips

Remove rear carpet RH duct bezel

Note

4x clips

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

Remove RH subwoofer

Note

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

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

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

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

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

Remove center floor lower support bracket

Note

4x clips

Remove center console riser duct

Note

2x clips, Maneuver forward to clear riser assembly

Remove floor jumper duct

Note

Push forward then lift and slide out

Remove 2nd row duct on rails

Note

Pull from the bottom to release

Release connectors from RCM

Note

2x connectors, Release locking tabs first

Release RCM from body

Note

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

Remove RCM from vehicle

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

Release floor harness from LH MV controller

Note

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

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

Release cabin floor and backbone harnesses from RH MV controller

Note

1x connector, 1x backbone cable, 2x edge clips, 3x harness clips, Pull from edges of connector housing, Do not pull backbone cable, Avoid bending cable at a tight radius

Disconnect rear display connector from car computer

Note

1x connector

Remove cabin floor harness

Note

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

Remove RH 2nd row floor duct

Note

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

Remove 2nd row floor Y-Duct

Note

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

Release front section of backbone

Note

3x harness clips, Pass connector under cabin floor harness

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

Remove backbone harness

Note

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

Partially release aft section of LH front fender flare cover

Note

11x clips, 3x datum, 1x connector total, Release as needed for clearance, Full removal not required

Remove LH front rocker fastener from step reinforcement

Note

1x bolt, 10mm, 4 Nm

Remove clip securing LH front wheel liner to rocker cover

Note

1x clip

Partially release fore section of LH rear fender flare cover

Note

13x clips, 3x datums total, Release as needed for clearance, Full removal not required

Remove LH rear rocker fastener from step reinforcement

Note

1x bolt, 10mm, 4 Nm

Remove clip securing LH rocker cover to rear wheel liner

Note

1x clip

Remove rocker cover fasteners from LH side ski

Note

6x bolts, 10mm, 10 Nm

Release LH rocker cover from rocker carrier

Note

11x clips, 1x datum, Remove any clips that remained on carrier

Remove front LH rocker step reinforcement

Note

3x bolts, 10mm, 15 Nm, 2x datums

Remove rear LH rocker step reinforcement

Note

3x bolts, 10mm, 15 Nm

Partially release aft section of front RH fender flare cover

Note

11x clips, 3x datum, 1x connector total, Release as needed for clearance, Full removal not required

Remove RH front rocker fastener from step reinforcement

Note

1x bolt, 10mm, 4 Nm

Remove clip securing RH rocker cover to front wheel liner

Note

1x clip

Partially release fore section of rear RH fender flare cover

Note

13x clips, 3x datums total, Release as needed for clearance, Full removal not required

Remove RH rear rocker fastener from step reinforcement

Note

1x bolt, 10mm, 4 Nm

Remove clip securing RH rocker cover to rear wheel liner

Note

1x clip

Remove rocker cover fasteners from RH side ski

Note

6x bolts, 10mm, 10 Nm

Release RH rocker cover from rocker carrier

Note

11x clips, 1x datum, Remove any clips that remained on carrier

Remove front RH rocker step reinforcement

Note

3x bolts, 10mm, 15 Nm, 2x datums

Remove rear RH rocker step reinforcement

Note

3x bolts, 10mm, 15 Nm

Roll vehicle forward

Note

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

Move vehicle onto lift

Note

Ensure positioning allows rear doors to open, NOTE: If burning odors, popping sounds, flames, or smoke is seen at any time, halt this process and call the fire department immediately! Begin evacuation if vehicle is in the shop.

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

Raise and support vehicle

Note

Set air suspension to "Jack Mode", Align lift adapter pins with lift point holes on body

Remove fastener covers from bed floor assembly

Note

6x covers

Remove bed floor assembly

Note

10x bolts, 15mm, 56 Nm, 4x anchors, Open anchors as needed, Lift front edge with trim tool then remove panel, Recommend assistance

Remove fasteners securing RH tonneau NVH barrier

Note

6x bolts, T25, 5 Nm, Vehicles built before April 2024 will have 1-piece NVH cover, 5x bolts, 8mm, 5 Nm, Vehicles built after April 2024 will have updated 1-piece NVH cover, 9x bolts, 4mm Allen, 5 Nm, Vehicles built after October 2024 will have 2-piece NVH cover*part number for bolts needed

Remove RH tonneau NVH barrier

Note

Vehicles built before April 2024 will have 1-piece NVH cover, Vehicles built after April 2024 will have updated 1-piece NVH cover, Vehicles built after October 2024 will have 2-piece NVH cover, Maneuver around bed wall then remove

Remove fasteners securing LH tonneau NVH barrier

Note

5x bolts, T25, 5 Nm, Vehicles built before April 2024 will have 1-piece NVH cover, 5x bolts, 8mm, 5 Nm, Vehicles built after April 2024 will have updated 1-piece NVH cover, 9x bolts, 4mm Allen, 5 Nm, Vehicles built after October 2024 will have 2-piece NVH cover

Remove LH tonneau NVH barrier

Note

Vehicles built before April 2024 will have 1-piece NVH cover, Vehicles built after April 2024 will have updated 1-piece NVH cover, Vehicles built after October 2024 will have 2-piece NVH cover, Maneuver around bed wall then remove

Remove bolts securing HV battery to RUB

Note

4x bolts, 21mm, 119 Nm, Break free before using power tools, Tonneau slats must be closed or removed to access forward bolts, Shown without tonneau for clarity

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

Remove bolt securing busbar HV connector lid

Note

1x bolt, EP10, 9 Nm

Remove bolts securing HV connector to DC FC header

Note

2x bolts, 10mm, 9 Nm

Release HV connector from DC FC header

Note

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

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

Disconnect HV ancillary harness

Note

1x connector, Release red locking tab then slide open black lever to remove

Raise vehicle fully

Note

Set to a comfortable working height, Lower to locks, Ensure locks engage on both sides to prevent tilting

Position coolant drain container underneath RH rear of HV battery

Remove RH rear wheel

Note

6x nuts, 21mm, 205 Nm

Secure RH rear wheel liner aside

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

Disconnect RDU supply hose

Note

1x spring clip, Plug hoses

Move coolant drain container to front right of HV battery

Remove RH front wheel

Note

6x nuts, 21mm, 205 Nm

Secure RH front wheel liner aside

Disconnect PT supply and return hoses

Note

2x spring clips, Plug hoses

Disconnect battery coolant supply and return hoses

Note

2x spring clips, Use caution with pick near HV harness, Plug Hoses, Position coolant drain as needed

Remove coolant drain container from underneath vehicle

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

Disconnect RDU HV harness

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

Release FDU HV harness

Note

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

Position battery table

Note

Ensure table is level

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

Remove side exterior HV battery mounting bolts from LH and RH side

Note

16x bolts, 15mm, 62 Nm

Raise vehicle away from HV battery

Note

Ensure no coolant hoses, harnesses, or brake lines are caught while lifting, If lift is shorter then remove rear wheels as needed

Remove HV battery from underneath vehicle

Note

Recommend assistance

Install HV battery alignment rods

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

Lower vehicle onto HV battery

Note

Ensure no coolant hoses, harnesses, or brake lines are caught while lowering, Recommend assistance to ensure good alignment whilst lowering

Install side exterior HV battery mounting bolts to LH and RH side

Note

16x bolts, 15mm, 60 Nm

Remove HV battery alignment rods from front casting

Note

2x alignment rods

Install front exterior HV Battery mounting bolts and ground strap

Note

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

Raise vehicle away from battery table

Note

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

Remove battery table from under vehicle

Install FDU HV harness

Note

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

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

Install RDU HV harness

Note

1x connector, 1x harness clip, Ensure locking tab is engaged

Install clips securing pressurized pack line

Note

3x clips

Position coolant drain container underneath RH rear of HV battery

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

Connect RDU supply hose

Note

1x spring clip, Remove coolant plugs, Perform a push-pull-push test to ensure hose is engaged

Move coolant drain container to front right of HV battery

Connect PT supply and return hoses

Note

2x spring clips, Remove plugs, Perform a push-pull-push test to ensure hose is engaged

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

Remove coolant drain container from underneath vehicle

Install Mid-aero shield

Note

6x clips, 3x bolts, 15mm, 70 Nm, 3x bolts, 13mm, 28 Nm, 2x bolts, 10mm, 6 Nm

Install front skid plate

Note

8x nuts, 15mm, 50 Nm, 2x bolts, 11mm, 50 Nm

Install front aero shield fasteners

Note

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

Install RH front wheel

Note

6x nuts, 21mm, 205 Nm

Install RH rear wheel

Note

6x nuts, 21mm, 205 Nm

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

Torque RH front wheel nuts

Note

6x nuts, 21mm, 205 Nm

Torque RH rear wheel nuts

Note

6x nuts, 21mm, 205 Nm

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

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

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

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

Install busbar onto HV header and install bolts

Note

2x bolts, 10mm, 9 Nm

Connect HV ancillary harnesse

Note

1x connector, Slide black lever to engage then push in red locking tab

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.

Put on HV insulating gloves and leather over gloves

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

Remove leather over gloves and HV insulating gloves

Install bolt securing busbar HV connector lid

Note

1x bolt, EP10, 9 Nm

Connect ancillary bay MV connector

Note

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

Position LH tonneau NVH barrier

Note

Vehicles built before April 2024 will have 1-piece NVH cover, Vehicles built after April 2024 will have updated 1-piece NVH cover, Vehicles built after October 2024 will have 2-piece NVH cover, Maneuver around bed wall then position

Install fasteners securing LH tonneau NVH barrier

Note

5x bolts, T25, 5 Nm, Vehicles built before April 2024 will have 1-piece NVH cover, 5x bolts, 8mm, 5 Nm, Vehicles built after April 2024 will have updated 1-piece NVH cover, 9x bolts, 4mm Allen, 5 Nm, Vehicles built after October 2024 will have 2-piece NVH cover

Position RH tonneau NVH barrier

Note

Vehicles built before April 2024 will have 1-piece NVH cover, Vehicles built after April 2024 will have updated 1-piece NVH cover, Vehicles built after October 2024 will have 2-piece NVH cover, Maneuver around bed wall then position

Install fasteners securing RH tonneau NVH barrier

Note

6x bolts, T25, 5 Nm, Vehicles built before April 2024 will have 1-piece NVH cover, 5x bolts, 8mm, 5 Nm, Vehicles built after April 2024 will have updated 1-piece NVH cover, 9x bolts, 4mm Allen, 5 Nm, Vehicles built after October 2024 will have 2-piece NVH cover

Install bed floor assembly

Note

12x short bolts, 15mm, 56 Nm, 2x long bolts, 15mm, 46Nm, Recommend assistance

Install fastener covers onto bed floor assembly

Note

14x covers

Position wheel chocks fore and aft of RH rear wheel

Remove vehicle from lift

Note

Lower rack arms fully and remove them from under vehicle,

Roll vehicle rearward

Note

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

Install backbone harness

Note

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

Inspect for presence of backbone harness guide at front casting

Note

Ensure backbone harness guide is installed

Secure front section of backbone

Note

3x clips, Route connector under cabin floor harness

Inspect for any misalignment at rear ribs and apply abrasion tape if missing

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

Install 2nd row floor Y-Duct

Note

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

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

Install cabin floor harness

Note

2x connectors, 5x clips, 2x bolts, 10mm, 10 Nm, Secure connector housings to seat riser crossmembers, Secure locking levers on RCM connectors

Position RCM for installation

Install RCM to body

Note

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

Secure connectors onto RCM

Note

2x connectors, Engage locking tabs

Install RH 2nd row floor duct

Note

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

Connect rear display connector to car computer

Note

1x connector

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

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

Secure floor harness onto LH MV controller

Note

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

Secure left MV controller connector locking frame

Note

1x bolt, 8mm, 4 Nm, Ensure connectors are aligned before tightening center bolt

Install RH interior front HV battery mounting bolts

Note

3x bolts, 24mm, 160 Nm

Install RH carpet support foam

Note

Seat at rear edge

Install LH front interior HV Battery mounting bolts

Note

3x bolts, 24mm, 160 Nm

Install LH carpet support foam

Note

Seat at rear edge

Install 2nd row dual duct on rails

Note

Maneuver as needed through foam insert

Install floor jumper duct

Note

2x clips

Install center console riser duct

Note

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

Install center floor lower support bracket

Note

4x clips, Replace any missing or damaged clips

Install center floor upper bracket

Note

2x push clips, 4x clips

Install RH front cabin carpet

Note

Plastic portions at rear of carpet need to clear risers

Install LH front cabin carpet

Note

Plastic portions at rear of carpet need to clear risers

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

Install LH seat riser assembly

Note

4x bolts, 13mm, 40 Nm, 2x clips, Install cabin MV harness onto LH seat riser assembly

Install LH outboard riser bolt cover

Install RH seat riser assembly

Note

4x bolts, 13mm, 40 Nm, 3x clips, Attach cabin MV harness and air duct to riser assembly

Install RH outboard riser bolt cover

Install LH rear carpet duct bezel

Note

4x clips, Replace any missing or damaged clips

Install rear carpet RH duct bezel

Note

4x clips, Replace any missing or damaged clips

Install center console

Note

Lower onto riser

Connect center console harness connectors

Note

2x connectors

Install front bolts securing center console to riser

Note

4x bolts, 10mm, 5 Nm

Install center console front panel

Note

10x clips, Replace any missing or damage clips

Install rear bolts securing center console to riser

Note

2x bolts, 10mm, 5 Nm

Install center console rear panel

Note

12x clips, 3x connectors, 3x harness clips, Replace any missing or damaged clips

Install LH front seat into vehicle

Note

Recommend assistance, Be cautious not to damage surrounding components while lifting the seat into the vehicle

Connect LH front seat harness

Note

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

Install RH front seat into vehicle

Note

Recommend Assistance, Be cautious not to damage surrounding components while lifting the seat into the vehicle

Connect RH front seat harness

Note

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

Remove HV battery alignment rods from stancion mounting holes on pack

Note

2x alignment rods

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

Install RH subwoofer

Note

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

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

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

Install rear wall lower trim

Note

2x push clips, 4x clips

Secure LH lower C-pillar trim

Note

1x clip, 1x datum

Fold down 2nd row 60 seat

Note

Pull tether to release then pivot down until locked in place

Secure RH lower C-pillar trim

Note

1x clip, 1x datum

Fold down 2nd row 40 seat

Note

Pull tether to release then pivot down until locked in place

Install 2nd row floor mat

Perform coolant system vauum refill. See Cooling System (Vacuum Refill).

Connect first responder loop and MV battery connector

Note

2x connectors, Connect FRL connector then secure locking tab, Position lever to secure MV battery connector then slide eCPA to right, Early production trucks may have black FRL connector, If power cycling vehicle then ensure at least 60 seconds has passed since powering down

Remove Universal Lift Pad adapters

Note

4x Adapters, Install original lift pads, Install plugs back into holes in BIW

Remove vehicle from lift

Note

Lower rack arms fully and remove them from under vehicle, Remove air suspension from "Jack Mode"

Select 'Procedures'

Note

Lighting Bolt Icon > High Voltage > Procedures

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)

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

Install front RH rocker step reinforcement

Note

3x bolts, 10mm, 15 Nm, 2x datums

Install rear RH step reinforcement

Note

3x bolts, 10mm, 15 Nm

Install RH rocker cover to rocker carrier

Note

11x clips, 1x datum

Install rocker cover fasteners to RH side ski

Note

6x bolts, 10mm, 10 Nm

Install clip securing RH rocker cover to rear wheel liner

Note

1x clip

Install RH rear rocker fastener to step reinforcement

Note

1x bolt, 10mm, 4 Nm

Secure fore section of rear RH fender flare cover

Note

13x clips, 3x datums total, Ensure no clips are damaged, Replace clips as required

Install clip securing RH rocker cover to front wheel liner

Note

1x clip

Install RH front rocker fastener to step reinforcement

Note

1x bolt, 10mm, 4 Nm

Secure aft section of front RH fender flare cover

Note

11x clips, 3x datum, 1x connector total, Ensure no clips are damaged, Replace clips as required

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.

Move RH front seat backward

Install bolts securing RH front seat front tracks to vehicle

Note

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

Install center floor trim

Note

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

Install RH center floor rail

Note

4x clips, 3x datums

Install RH lower A-pillar trim

Note

7x clips, 3x datums, 2x tabs

Install RH mid A-pillar trim

Note

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

Install RH front floor mat

Move RH front seat forward

Install bolts securing RH front seat rear tracks to vehicle

Note

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

Install LH front rocker step reinforcement

Note

3x bolts, 10mm, 15 Nm, 2x datums

Install rear LH step reinforcement

Note

3x bolts, 10mm, 15 Nm

Install LH rocker cover to rocker carrier

Note

11x clips, 1x datum, Replace any missing or damaged clips

Install rocker cover fasteners to LH side ski

Note

6x bolts, 10mm, 10 Nm

Install clip securing LH rear wheel liner to rocker cover

Note

1x clip

Install LH rear rocker fastener to step reinforcement

Note

1x bolt, 10mm, 4 Nm

Secure fore section of LH rear fender flare cover

Note

13x clips, 3x datums total, Replace any missing or damaged clips

Install clip securing LH front wheel liner to rocker cover

Note

1x clip

Install LH front rocker fastener to step reinforcement

Note

1x bolt, 10mm, 4 Nm

Secure aft section of LH front fender flare cover

Note

11x clips, 3x datum, 1x connector total, Replace any missing or damaged clips

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

Move LH front seat backward

Install bolts securing both LH front seat front tracks to vehicle

Note

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

Install LH center floor rail

Note

4x clips, 3x datums

Install accelerator pedal

Note

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

Install accelerator pedal side trim

Note

3x clips, Replace any missing or damaged clips

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

Install LH Lower A-pillar trim

Note

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

Install LH mid A-pillar trim

Note

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

Install LH front floor mat

Move LH front seat forward

Install bolts securing LH front seat rear tracks to vehicle

Note

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

Inspect coolant level and top off as necessary

Note

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

Install coolant bottle cap

Install rear underhood apron

Note

9x clips, Adjust windshield seal as required

Close powered front trunk

Note

Via frunk switch or UI

Perform Thermal Performance Test through the UI

Note

Select Thermal > Actions > Test Thermal Performance, click Run, close once routine is completed, if thermal test fails follow toolbox article 206000

Position tonneau transfer frame onto tonneau bed rails

Note

Lay tonneau chain on tailgate and secure ends to prevent breakdown or shifting, Use tape or bungees as needed, Connect air supply, Raise and adjust angle on powertrain table as needed

Manually guide remaining tonneau slats and chain onto bed rails

Note

Recommend assistance, 2x pins, Evenly guide slats in then install pins, Monitor Y reaction clips entering bed rails and ensure clips do not bind, Monitor slats during install and ensure all are squared during install, Adjust as needed

Secure tonneau chain onto motors

Note

Recommend assistance, Press open button until both motors have audibly secured all links and cover is fully open

Remove tonneau transfer frame from tonneau bed rails

Note

Disconnect air supply, Lower and adjust angle on powertrain table as needed

Install RH tailgate bumpstop

Note

1x datum, Rotate and secure

Install RH tonneau slip datum bracket

Note

(*Could not locate part number in catalog)

Install RH tonneau hard stop

Note

3x bolts, 10mm, 9 Nm, Hand start center black locating bolt first, Set 2mm space between datum and end of bed rail(*Could not locate part number in catalog)

Secure RH rear lamp closeout applique

Note

2x clips, 2x datums

Install RH tonneau water management seal

Note

1x clip, Push seal into rail groove

Secure RH sail applique

Note

6x tabs, Remove inflatable air bag, Clean off double sided tape from sail and applique, Clean with IPA wipes and allow 1 minute dry time, Cut same length tape and apply

Secure LH tailgate bumpstop

Note

1x datum, Rotate and secure

Install LH tonneau slip datum bracket

Note

(*Could not locate part number in catalog)

Install LH tonneau hard stop

Note

3x bolts, 10mm, 9 Nm, Hand start center black locating bolt first, Set 2mm space between datum and end of bed rail(*Could not locate part number in catalog)

Secure LH rear lamp closeout applique

Note

2x clips 2x datums

Install LH tonneau water management seal

Note

1x clip, Push seal into rail groove

Secure LH sail applique

Note

6x tabs, Remove inflatable air bag, Clean off double sided tape from sail and applique, Clean with IPA wipes and allow 1 minute dry time, Cut double sided tape to length and apply