2026-06-02

Device Cluster (Standard) (Remove and Replace)

Correction code 16300107302 3.54 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.

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.

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.

2026-06-02: Updated entire procedure to latest time study.
2026-04-27: Released new procedure.

Remove

Raise and support the vehicle. See Raise Vehicle - 2 Post Lift.
Open the LH front door and lower the LH front window.
Open the powered frunk.
Open the tailgate.
Open the tonneau cover.
Place the vehicle into Service Mode. See Service Mode.
Unlock the vehicle Gateway. See Gateway (Unlock).
Remove the tonneau slats. See Slat System - Tonneau (Remove and Install).
Run ODIN routine PROC_ICE_X_ENTER-SERVICE-MODE-PLUSvia Toolbox:(link)
Run ODIN routine PROC_HVBATT_X_DEVICE-CLUSTER-REPLACEMENT-BACKUPvia Service Mode Plus:High Voltage Battery ➜ Device Cluster Assembly (DCA) Replacement ➜ Backup Old DCAvia Toolbox:(link)
Disconnect MV power. See Mid-Voltage Power (Disconnect and Connect) (Modify).
Perform vehicle HV disablement procedure. See Vehicle HV Disablement Procedure (Test/Adjust).
Remove pyro fuse access cover

Note
4x bolts, E-Torx 5 lobe, 10 Nm*Use this step for coil suspension truck procedures (non-air suspension)
Remove primary and secondary pyro fuses

Note
4x bolts, 13mm, 5 Nm + 60 Degrees, Support each pyro fuse while removing bolts
Partially install pyro fuse access cover to protect ancillary from contaminates, debris, or coolant ingress during service

Note
4x bolts, E-Torx 5 lobe, 10 Nm, Tighten until snug, Torque not required at this time, only temporary installation
Release connectors at 2x4 header (AC compressor and Inductive Charger headers)

Note
2x connectors, Fully release red lock tab, Pull black latch down to release connector
Release 2x4 header assembly

Note
4x bolts, 5-lobe 10mm, 6 Nm
Release drive unit connectors from ancillary headers

Note
3x connectors, Release blue lock tab, Rotate black latch
Remove bolts securing HC-Stak HV Headers for LHRDU, FDU, RHRDU from ancillary flange

Note
6x bolts, 5-lobe 10mm, 10 Nm
Remove LHRDU, FDU, RHRDU headers from ancillary flange

Note
3x headers, No tools required, inspect header seals, Replace header if damaged
Remove leather over gloves and HV insulating gloves
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
Remove the bed floor assembly. See Bed Floor Assembly (Long Range) (Remove and Install).
Install Ancillary Access Bench into bed floor opening.

Note
1x bench, place above rear casting ensuring no air lines or harnesses are being pinched(*No image available or access bench in LONG RANGE/STANDARD truck bed)
Remove the tonneau NVH barrier. See Tonneau NVH Barrier Assembly (Standard) (Remove and Install).
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)
Clean all debris from ancillary cover

Note
During removal of ancillary cover any debris on top of the cover may be deposited into the ancillary bay
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 mid voltage header bolts

Note
2x bolts, EP10, 6 Nm
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
Remove fast charger header doubler

Note
2x bolts, E10 5 Lobe Torx, 10 Nm
Release fasteners securing ancillary 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
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
Remove ancillary cover

Note
Install vacuum cup to ancillary cover surface, Lift and maneuver cover around busbar and tonneau cage to remove
Remove fast charge HV connector 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
Release MV header from device cluster assembly

Note
4x datums, 1x edge clip, 1x fir tree clip
Release HVC connectors from device cluster assembly

Note
2x clips, 3x connectors, Release connector locks, Depress levers and pull at connector, Do not pull from harnessIf RTV is present at 2 connectors, using a ceramic knife cut through and remove RTV until connector can be disconnected.*Replacement Device clusters with newer REV do not require sealant at connections.*If reinstalling the same Device cluster (not replacing) re-apply grey sealant during the installation process if sealant was present during removal.
Release BMB passthrough connectors

Note
2x connectors, Release connector locks, Depress levers and pull at connector, Do not pull from harness
Release ACJB LV connector & ACJB to device cluster HV connector

Note
2x clips, 2x connectors, Release connector locks, Depress levers and pull at connectors, Do not pull at harness, inspect ACJB to DC HV harness part number, if not rev J or newer, replace harness
Move ancillary harness aside

Note
Lay loose section of ancillary harness on top of PCS out of work area
Release device cluster HV harness from PCS

Note
1x connectors, Release connector lock, Depress lever and pull at connector, Do not pull at harness
Release device cluster busbar fasteners

Note
4x bolts, Torx Plus 55, 5Nm + 60 Degrees, Captured bolts with insulated covers
Remove device cluster assembly fasteners

Note
4x bolts, E10 5 Lobe Torx, 6Nm
Remove device cluster from ancillary tray

Note
Place device cluster on stand to protect headers at bottom of assembly, Remove lifting/install tool, Make sure to wear PPE (HV gloves, safety glasses) when working on high voltage component

Install

Position device cluster to ancillary tray

Note
Align datums and headers to ancillary and slowly lower into place, Avoid contact of drive unit headers to ancillary tray, Make sure to wear PPE (HV gloves, safety glasses) when working on high voltage component
Secure device cluster assembly fasteners

Note
4x bolts, E10 5 Lobe Torx, 6Nm
Secure device cluster busbar fasteners

Note
4x bolts, Torx Plus 55, 5Nm + 60 Degrees, Captured bolts with insulated covers
Perform Hioki measurements from device cluster assembly and busbar bolts

Note
1x bolts, E10 5 Lobe Torx, 6Nm, 4x bolts, Torx Plus 55, 5Nm + 60 Degrees, Perform zero adjust to Hioki meter prior to testingUse diagram in images to find probing locations and the reading specifications to look forLSL means: Lower Specification LimitUSL means: Upper Specification Limit1020_301 | T1 LSL 0.002 mΩ (2 μΩ) - USL 0.05 mΩ (50 μΩ)1020_304 | POS Contactor LSL 0.002 mΩ (2 μΩ) - USL 0.05 mΩ (50 μΩ)1010_603 | HVC Ground strap LSL 0.35 mΩ (350 μΩ) - USL 0.78 mΩ (780 μΩ)1020_303 | Shunt2 LSL 0.003 mΩ (3 μΩ) - USL 0.05 mΩ (50 μΩ)1020_302 | Shunt1 LSL 0.003 mΩ (3 μΩ) - USL 0.05 mΩ (50 μΩ)If readings are lower than the LSL numbers you are not probing correctlyIf readings are higher than USL numbers you have bolts that are not torqued correctly or connectors that may be softset or have internal connector issues
Secure device cluster HV harness to PCS

Note
1x connectors, Secure connector lock
Secure ACJB LV and HV connectors

Note
2x clips, 2x connectors, Secure connector locks
Secure BMB passthrough connectors

Note
2x connectors, Secure connector locks, Connectors are poke yoked do not force engagement, Ensure locking tabs are facing front of vehicle when connecting
Secure HVC connectors to device cluster assembly

Note
2x clips, 3x connectors, Release connector locks, Depress levers and pull at connector, Do not pull from harness*Replacement Device clusters with newer REV do not require sealant at connections.*If reinstalling the same Device cluster (not replacing) re-apply grey sealant to device cluster connectors during the installation process if sealant was present during removal.
Secure MV header to device cluster assembly

Note
4x datums, 1x edge clip, 1x fir tree clip
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
Install ancillary cover

Note
Use suction cup and maneuver around busbar and tonneau cage
Remove leather over gloves and HV insulating gloves
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
Install fast charger header doubler

Note
2x bolts, E10 5 Lobe Torx, 10Nm
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
Position busbar connector and lower onto HV header

Note
Release bungee cord
Install bolts securing charge port busbar kit to HV Header

Note
2x bolts, 10mm, 9 Nm
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
Install bolt securing busbar HV connector lid

Note
1x bolt, EP10, 9 Nm
Install mid voltage header bolts

Note
2x bolts, EP10, 6 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
Install two rear tonneau square profile support braces

Note
8x screws, T30, 5 Nm, Install two square support 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
Install the tonneau NVH barrier. See Tonneau NVH Barrier Assembly (Standard) (Remove and Install).
Install the bed floor assembly. See Bed Floor Assembly (Long Range) (Remove and Install).
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
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
Install LHRDU, FDU, RHRDU headers to ancillary flange

Note
3x headers, No tools required, inspect header seals, Replace header if damaged
Secure bolts to HC-Stak HV Headers for LHRDU, FDU, RHRDU to ancillary flange

Note
6x bolts, 5-lobe 10mm, 10 Nm
Secure 2x4 header assembly

Note
4x bolts, 5-lobe 10mm, 6 Nm, Confirm alignment of assembly with fastener openings
Secure connectors at 2x4 header (AC compressor and Inductive Charger headers)

Note
2x connectors, Fully engage red lock tab
Secure drive unit connectors to ancillary headers

Note
3x connectors, Rotate black latch, Ensure blue locking tab is fully engaged
Remove partially installed pyro fuse access cover

Note
4x bolts, E-Torx 5 lobe, 10 Nm
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
Install primary and secondary pyro fuses

Note
4x bolts, 13mm, 5 Nm + 60 Degrees, Support each pyro fuse while installing bolts, Bolts may be reused
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
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
Remove leather over gloves and HV insulating gloves
Install the rear skid plate. See Skid Plate - Rear (Remove and Install).
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
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
Run ODIN routine PROC_ICE_X_ENTER-SERVICE-MODE-PLUSvia Toolbox:(link)
Restore Device Cluster Assembly

Note
Via Service UI> High Voltage Tab > Procedures > Device Cluster Assembly Replacement > Restore New DCA > Run, Laptop must be connected via Toolbox 3 for duration of routine, Follow all on screen instructions and requirements, Do not disconnect Toolbox 3 until routine completes successfully
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
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
Reconnect MV power. See Mid-Voltage Power (Disconnect and Connect) (Modify).
Install the rear underhood apron. See Underhood Apron - Rear (Remove and Install).
Install the tonneau slats. See Slat System - Tonneau (Remove and Install).
Install the tonneau slats. See Slat System - Tonneau (Remove and Install).
Exit Service Mode. See Service Mode.
Close the tailgate, tonneau cover, and powergate.
Raise the LH front window and close the LH front door.
Remove the vehicle from the lift. See Raise Vehicle - 2 Post Lift.

Cybertruck Service Manual

Device Cluster (Standard) (Remove and Replace)

Remove

Install

Figure 1

Figure 2

Figure 3