Correction code NEW NOTE: Unless otherwise explicitly stated in the procedure, the correction code and FRT listed above 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. Raise and support vehicle
   Note

   If vehicle has air suspension set to Jack Mode", Align lift adapter pins with lift point holes on body, Ensure vehicle is not charging, Remove charging cable if it's plugged in
2. Open powered front trunk
   Note

   Via exterior switch or UI
3. Open tailgate
   Note

   Press button to release, Use manual release as necessary
4. Remove the tonneau slats. See Slat System - Tonneau (Remove and Install).
5. 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
6. Remove rear underhood apron
   Note

   9x clips

   

   

7. 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

   

   

   

8. 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

   

   

9. 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
10. 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)

    

    

    

    

    

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

    This includes phones, badges, metal belt buckles airpods and headphones

    

12. 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.

    

13. 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

    

14. 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

    

    

    

    

    

    

15. Secure RDU header connector to ancillary
    Note

    1x connector, Verify lever is in the upright and open position, Carefully seat connector and allow lever to engage, Fully secure lever and verify red tab is locked, Do not damage any pins

    

    

16. Remove pyro fuse access cover
    Note

    4x bolts, E-Torx 5 lobe, 10 Nm

    

17. Remove primary pyro fuse
    Note

    2x bolts, 13mm, 5 Nm + 60 Degrees, Support pyro fuse while removing bolts

    

    

18. Remove secondary pyro fuse
    Note

    2x bolts, 13mm, 5 Nm + 60 Degrees, Support pyro fuse while removing bolts

    

    

19. Install pyro fuse access cover
    Note

    4x bolts, E-Torx 5 lobe, 10 Nm, Ensure seal is fully seated and undamaged, If HV pack is being shipped then pyro fuses must be removed

    

    

20. Remove leather over gloves and HV insulating gloves
21. 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
22. Remove fastener covers from bed floor assembly
    Note

    14x covers

    

    

    

    

    

23. Remove bed floor assembly
    Note

    12x short bolts, 15mm, 56 Nm, 2x long bolts, 15mm, 46Nm, Lift front edge with trim tool then remove panel, Recommend assistance

    

    

    

    

24. 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

    

    

    

    

    

25. Put on HV insulating gloves and leather over gloves

    

26. Remove bolt securing busbar HV connector lid
    Note

    1x bolt, EP10, 9 Nm

    

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

    2x bolts, 10mm, 9 Nm

    

28. Release HV connector from DC FC header
    Note

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

    

29. 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

    

    

30. Remove fast charger header doubler
    Note

    2x bolts, E10 5 Lobe Torx, 10 Nm

    

    

31. Remove mid voltage header bolts
    Note

    2x bolts, EP10, 6 Nm

    

32. Release fasteners securing ancillary bay cover to HV battery
    Note

    22x bolts, E10 5-Lobe, 6 Nm, Use E10 5-Lobe socket without magnet, The fasteners are captive and will stay attached to the penthouse cover, Follow fastening order

    

    

    

33. Remove ancillary bay cover
    Note

    Install vacuum cup to ancillary bay cover surface, Lift and maneuver cover around busbar and tonneau cage to remove

    

    

    

34. Remove DC header
    Note

    1x connector, 1x tree clip, connector is hidden under the seal, lift up the seal to see, Slide header off DC bus links, Inspect seal, Replace header if damaged

    

    

    

35. Install DC header
    Note

    1x connector, 1x tree clip, Slide header on to DC bus links, connector is hidden under the seal, Inspect seal, Replace header if damaged

    

    

    

    

36. Install ancillary cover
    Note

    Use suction cup and maneuver around busbar and tonneau cage

    

    

    

    

37. Secure ancillary cover fasteners to HV battery
    Note

    22x bolts, E10 5-Lobe, 6 Nm, Use E10 5-Lobe socket without magnet, The fasteners are captive and will stay attached to the penthouse cover, Follow fastening order

    

    

    

38. Install mid voltage header bolts
    Note

    2x bolts, EP10, 6 Nm

    

39. Install fast charger header doubler
    Note

    2x bolts, E10 5 Lobe Torx, 10Nm

    

    

40. 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

    

41. 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

    

42. 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

    

43. Position busbar connector and lower onto HV header
    Note

    Release bungee cord

    

44. Install bolts securing charge port busbar kit to HV Header
    Note

    2x bolts, 10mm, 9 Nm

    

45. 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

    

    

46. Install bolt securing busbar HV connector lid
    Note

    1x bolt, EP10, 9 Nm

    

47. Connect ancillary bay MV connector
    Note

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

    

    

    

    

    

48. 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
49. Remove pyro fuse access cover
    Note

    4x bolts, E-Torx 5 lobe, 10 Nm

    

50. Clean pyro fuse mating surfaces
    Note

    Using an insulated tool wipe all four busbar mating surfaces within pyro fuse bay, Wipe top and bottom mating surfaces of each pyro fuse, Ensure no debris is present on any mating surface, Process shown with device cluster removed for clarity and safety, HV gloves and associated PPE must be worn at all times when cleaning mating surfaces, Allow 1 minute for IPA to dry

    

    

    

51. Install secondary pyro fuse
    Note

    2x bolts, 13mm, 5 Nm + 60 degrees, Support pyro fuse while installing bolts, Bolts may be reused

    

    

52. Install primary pyro fuse
    Note

    2x bolts, 13mm, 5 Nm + 60 degrees, Support pyro fuse while installing bolts, Bolts may be reused

    

    

53. Perform Hioki resistance test at each HV joint from HV busbar lead to pyro fuse busbar
    Note

    4x 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

    

    

54. Install pyro fuse access cover
    Note

    4x bolts, E-Torx 5 lobe, 10 Nm, Ensure seal is fully seated and undamaged, If HV pack is being shipped then pyro fuses must be removed

    

    

55. Remove leather over gloves and HV insulating gloves
56. Install rear skid plate
    Note

    6x clips, 3x bolts, 15mm, 42 Nm, 5x bolts, 13mm, 28 Nm, 2x bolts, 10mm, 6 Nm, Apply Loctite 222 to mid aero shield bolts and install fasteners

    

    

    

    

    

57. Lower vehicle fully
    Note

    Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
58. 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

    

    

    

59. Install rear underhood apron
    Note

    9x clips, Adjust windshield seal as required

    

    

60. Close powered front trunk
    Note

    Via frunk switch or UI
61. Install bed floor assembly
    Note

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

    

    

    

    

    

62. Install fastener covers onto bed floor assembly
    Note

    14x covers

    

    

    

    

63. Install the tonneau slats. See Slat System - Tonneau (Remove and Install).
64. Close tailgate
65. Remove vehicle from lift
    Note

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