2026-08-09

Ancillary Cover (Remove and Install)

Correction code 1630010101 1630010102 FRT 3.18 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.

  • 2025-11-10: VOSS fittings are reusable. Removed steps that instructed to discard fitting.
  • 2024-11-22: Added warning to NOT skip steps to remove the tonneau slats.
  • 2024-04-10: Added step to install Ancillary Access Bench (2035746-00-A)
Warning
DO NOT SKIP the steps to remove the tonneau slats. Work on or around the ancillary bay REQUIRES the removal of the tonneau slats. Failure to remove the tonneau slats while working on or around the ancillary bay will result in conditions that may cause personal injury.
Warning
Cybertruck electronics are powered by a 48V "mid voltage" or "MV" architecture that is designed to improve efficiency. Servicing MV components requires extra knowledge and care in order to avoid personal and/or vehicular harm. Read and understand MV precautions in Electrical Precautions and make sure any required MV-related training courses have been completed, as applicable.
Warning
Only technicians who have been trained in High Voltage Awareness and have completed all required certification courses (if applicable) are permitted to perform this procedure. Proper personal protective equipment (PPE) and insulating HV gloves with a minimum rating of class 0 (1000V) must be worn at all times a high voltage cable, busbar, or fitting is handled. Refer to Tech Note TN-15-92-003, High Voltage Awareness Care Points for additional glove and safety information.
Warning
This procedure is a DRAFT. Although it has been validated, Warnings and Cautions might be missing. Follow safety requirements and use extreme caution when working on or near High Voltage systems and components.

Remove

  1. Raise and support the vehicle. See Raise Vehicle - 2 Post Lift.
  2. Remove the tonneau slats. See Slat System - Tonneau (Remove and Install).
  3. Remove the rear underhood apron. See Underhood Apron - Rear (Remove and Install).
  4. Disconnect MV power. See Mid-Voltage Power (Disconnect and Connect) (Modify).
  5. Perform Vehicle HV Disablement procedure. See Vehicle HV Disablement Procedure (without Terrestrial Armor) (Test/Adjust).
  6. Disconnect the pressurized pack lines.
    Note
    12 mm, 8 Nm
  7. Secure the RDU header connector to the ancillary.
    Note
    x1 connector
    Note
    Verify the lever is in the upright and open position. Carefully seat connector and allow the lever to engage. Fully secure the lever and verify that the red tab is locked.
    CAUTION
    Do not damage any pins.
  8. Remove the pyro access cover. See Cover - Pyro Access - HV Battery (Remove and Install).
  9. Remove the primary and secondary pyro fuses. See Pyro Disconnect (Remove and Install).
  10. Remove the leather over gloves and HV insulating gloves.
  11. Lower the vehicle until the tires are touching the ground.
  12. Remove the bed floor assembly. See Bed Floor Assembly (Remove and Install).
  13. Remove the bolts (x6) that attach the RH tonneau NVH cover.
    5 Nm (3.7 lbs-ft)
    Tip
    Use of the following tool(s) is recommended:
    • 10 mm socket
    Note
    2-peice NVH assembly order of operations requires RH side to be released first to allow busbar clearance for LH side removal.
  14. Remove the RH tonneau NVH cover.
    Note
    Release rearward, and then slide over the LH side NVH cover before removing upward.
  15. Remove the bolts (x5) that attach the LH tonneau NVH cover.
    5 Nm (3.7 lbs-ft)
    Tip
    Use of the following tool(s) is recommended:
    • 10 mm socket
  16. Remove the LH tonneau NVH cover.
    Note
    Slide towards the center. Ensure busbar clearance during removal to avoid damage to the NVH material.
  17. Remove the screws (x8) that attach the tonneau coverbox cross supports.
    5 Nm (3.7 lbs-ft)
    Tip
    Use of the following tool(s) is recommended:
    • Torx T25 socket
  18. Clean all debris from the ancillary cover.
    Note
    During the removal of the ancillary cover, any debris on top of the cover may be deposited into the ancillary bay.
  19. Release the pressurize pack air line from the ancillary.
    Note
    x1 connector
    CAUTION
    Do not release air line to the reservoir. Rapid loss of pressure will result if the wrong air line is released.
  20. Disconnect the electrical connector, and then remove the bolt that attaches the pressurize pack valve block to the air suspension reservoir.
    5 Nm (3.7 lbs-ft)
    Tip
    Use of the following tool(s) is recommended:
    • 10 mm socket
    Note
    x1 clip, x1 zip tie
    Note
    Release the lock before disengaging the connector.
    Note
    Cut the zip tie at the reservoir/ancillary air line bundle.
    Note
    Release the harness clip at the bracket.
  21. Release the air suspension valve block.
    Note
    x3 rubber grommets
    Note
    Rotate clockwise until the top 2 rubber feet have released from the bracket. Pull upwards at a 45 degree angle to release the bottom rubber foot from the bracket.
    Note
    Leave all air lines and connections secured, and then set the assembly aside.
  22. Remove the nuts (x2) that attach the air suspension reservoir to the body.
    33 Nm (24.3 lbs-ft)
    Tip
    Use of the following tool(s) is recommended:
    • 13 mm socket
    Note
    x2 fir tree clips
  23. Put the air suspension reservoir in service position, and then install the Ancillary Access Bench (2035746-00-A).
    Note
    Raise and swing the air suspension reservoir to the side of the bed.
  24. Disconnect the ancillary bay MV electrical connector.
    Note
    Double locking: Release the tab, and then pivot the lever. Release the second tab to disengage the electrical connector. Wait 1 second between locking tab release to discharge and prevent arcing.
  25. Remove the bolt that attaches the busbar HV connector lid.
    9 Nm (6.6 lbs-ft)
    Tip
    Use of the following tool(s) is recommended:
    • 10 mm socket
  26. Remove the bolts (x2) that attach the HV connector to the DC FC header.
    9 Nm (6.6 lbs-ft)
    Tip
    Use of the following tool(s) is recommended:
    • 10 mm socket
  27. Release the HV connector from the DC FC header, and then use an inflatable airbag to suspend the busbar assembly above the ancillary assembly.
    Note
    Upon separation, check for grease around the inner perimeter of the DC FC header. If present, additional steps will need to be performed later.
  28. Support the HV busbar assembly to maintain clearance with a bungee cord.
  29. Remove the bolts (x2) that attach the fast charger header doubler.
    10 Nm (7.4 lbs-ft)
    Tip
    Use of the following tool(s) is recommended:
    • External Torx E10 5-Lobe
  30. Remove the bolts (x2) that attach the low voltage header.
    6 Nm (4.4 lbs-ft)
    Tip
    Use of the following tool(s) is recommended:
    • 10 mm socket
  31. Remove the bolts (x22) that attach the ancillary cover to the HV battery.
    6 Nm (4.4 lbs-ft)
    Tip
    Use of the following tool(s) is recommended:
    • External Torx E10 5-Lobe
    Note
    Use E10 5-Lobe socket without magnet.
    Note
    The bolts are captive and will stay attached to the ancillary cover. Follow fastening order.
  32. Remove the ancillary cover.
    Note
    Use a suction cup and maneuver around the busbar and the tonneau cage.
  33. If grease was found around the inner perimeter of the DC FC header, use a disposable towel to wipe the grease off the header and the busbar connector.
    Note
    Do not allow the grease to contact the busbar HV mating surfaces.

Install

  1. Install the ancillary cover.
    Note
    Use a suction cup.
    Note
    Maneuver around the busbar and tonneau cage.
  2. Install the bolts (x22) that attach the ancillary cover to the HV battery.
    6 Nm (4.4 lbs-ft)
    Tip
    Use of the following tool(s) is recommended:
    • External Torx E10 5-Lobe
    Note
    Use E10 5-Lobe socket without magnet.
    Note
    The bolts are captive and will stay attached to the ancillary cover. Follow fastening order.
  3. Install the bolts (x2) that attach the low voltage header.
    6 Nm (4.4 lbs-ft)
    Tip
    Use of the following tool(s) is recommended:
    • 10 mm socket
  4. Install the bolts (x2) that attach the fast charger header doubler.
    10 Nm (7.4 lbs-ft)
    Tip
    Use of the following tool(s) is recommended:
    • External Torx E10 5-Lobe
  5. If grease was found inside the DC FC header, prepare the grease gun with Mobil XTCE grease, apply a 6 mm diameter continuous bead around the DC FC header inner perimeter, and then use a gloved finger wetted with alcohol to smear the grease up the inner wall to a height of 10 mm.
    Note
    The grease is part number 1089958-00-A and is available from eProcurement.
  6. Clean the HV connector contact surface of residual Penetrox with IPA wipe.
    Note
    Allow 1 minute dry time after removing Penetrox.
  7. Clean the busbar HV connector contact surface of residual Penetrox with an Isopropyl Alcohol (IPA) wipe.
    Note
    Allow 1 minute dry time after removing Penetrox.
    Note
    It is necessary to clean the HV connector during re-use of the busbar.
  8. Apply Penetrox onto the HV connector joints.
    Note
    Apply 2 drops of Penetrox A-13 about 5 mm in diameter to either side of the hole on both leads. Spread evenly to verify the contact surface is fully covered.
  9. Position the busbar connector, and then lower it onto the HV header.
    Note
    Remove the bungee cord.
  10. Install the bolts (x2) that attach the charge port busbar kit to the HV header.
    9 Nm (6.6 lbs-ft)
    Tip
    Use of the following tool(s) is recommended:
    • 10 mm socket (insulated)
  11. Inspect the HV insulating gloves.
    Note
    Check the gloves for damage prior to use. Refer to service document TN-15-92-003 for information on inspecting HV gloves.
  12. Put on the HV insulating gloves and leather over gloves.
  13. Perform a Hioki resistance test at each HV joint from the HV busbar lead to the bolt head.
    Note
    x2 HV joints
    Note
    When using a Hioki tester, verify the meter has been properly adjusted and set prior to usage.
    Note
    The 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), there is too much resistance in the High Voltage joint. Remove the fastener, clean areas with isopropyl alcohol, install fastener back and test again.
    • 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), the Hioki test passed. proceed to the next step.
  14. Remove the leather over gloves and HV insulating gloves.
  15. Install the bolt that attaches the busbar HV connector lid.
    9 Nm (6.6 lbs-ft)
    Tip
    Use of the following tool(s) is recommended:
    • 10 mm socket
  16. Connect the ancillary bay MV electrical connector.
    Note
    Double locking: Rotate the lever into the second lock. Perform a pull test to ensure the electrical connector is engaged correctly.
  17. Install the screws (x8) that attach the tonneau coverbox cross supports.
    5 Nm (3.7 lbs-ft)
    Tip
    Use of the following tool(s) is recommended:
    • Torx T25 socket
    Note
    Supports install in the same direction of the fasteners.
  18. Install the LH tonneau NVH cover.
    Note
    Make sure the busbar clearance during installation to avoid damage to the NVH material.
  19. Install the bolts (x5) that attach the LH tonneau NVH cover.
    5 Nm (3.7 lbs-ft)
    Tip
    Use of the following tool(s) is recommended:
    • 10 mm socket
  20. Install the RH tonneau NVH cover.
  21. Install the bolts (x6) that attach the RH tonneau NVH cover.
    5 Nm (3.7 lbs-ft)
    Tip
    Use of the following tool(s) is recommended:
    • 10 mm socket
  22. Remove the Ancillary Access Bench, and then put the air suspension reservoir into position for installation.
  23. Install the nuts (x2) that attach the air suspension reservoir.
    33 Nm (24.3 lbs-ft)
    Tip
    Use of the following tool(s) is recommended:
    • 13 mm socket
    Note
    x2 fir tree clips
  24. Secure the air suspension valve block.
    Note
    x3 rubber grommets
    Note
    Rotate counterclockwise until the top 2 rubber feet are secured onto the bracket. Push downwards at a 45 degree angle to secure the bottom rubber foot into bracket.
    Note
    Position air lines and connections into place for installation.
  25. Secure the pressurize pack air line from the ancillary to the valve block.
    Note
    x1 line
    Note
    Remove the plastic cap from the VOSS fittings. Press the air lines into the fitting until the mark aligns with the top of the fitting. Verify the line is properly secured by performing a push-pull test.
  26. Install the bolt that attaches the pressurize pack valve block to the air suspension reservoir, and then connect the electrical connector.
    5 Nm (3.7 lbs-ft)
    Tip
    Use of the following tool(s) is recommended:
    • 10 mm socket
    Note
    x1 clip, x1 zip tie
    Note
    Secure the reservoir and ancillary air lines at the white marked sections.
  27. Install the bed floor assembly. See Bed Floor Assembly (Remove and Install).
  28. Fully raise the vehicle.
  29. Inspect the HV insulating gloves.
    Note
    Check gloves for damage prior to use. Refer to service document TN-15-92-003 for information on inspecting the HV gloves.
  30. Put on the HV insulating gloves and leather over gloves.
  31. Clean the mating surface of the pyro.
    Note
    Use a non-conductive plastic tool to clean the busbar side. Allow 1 minute for the Isopropyl Alcohol (IPA) to fully dry.
    CAUTION
    Do not use any other types of cleaner.
  32. Install the primary and secondary pyro fuses. See Pyro Disconnect (Remove and Install).
  33. Remove the leather over gloves and HV insulating gloves.
  34. Install the bolts (x4) that attach the pyro fuse access cover.
    10 Nm (7.4 lbs-ft)
    Tip
    Use of the following tool(s) is recommended:
    • External Torx E10 5-Lobe
    Note
    Make sure that the seal is fully seated and undamaged.
  35. Install the pressurized pack lines (x2).
    8 Nm (5.9 lbs-ft)
    Tip
    Use of the following tool(s) is recommended:
    • 12 mm 6 point flare nut wrench
    • 12 mm flare nut crowfoot socket
    Note
    Remove the plastic caps from the VOSS fittings. Press the air lines into the fitting until the mark aligns with the top of the fitting. Verify the line is properly secured by performing a push-pull test.
  36. Install the mid aero shield.
    Note
    x6 clips; x3 bolts, 15 mm, 42 Nm; x5 bolts, 13 mm, 28 Nm; x2 bolts, 10 mm, 6 Nm
    Note
    Apply Loctite 222 onto mid aero shield bolts and install the fasteners.
  37. Fully lower the vehicle.
  38. Connect MV power. See Mid-Voltage Power (Disconnect and Connect) (Modify).
  39. Install the rear underhood apron. See Underhood Apron - Rear (Remove and Install).
  40. Close the powered frunk.
  41. Install the tonneau slats. See Slat System - Tonneau (Remove and Install).
  42. Remove the vehicle from the lift. See Raise Vehicle - 2 Post Lift.