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. Remove the tonneau slats. See Slat System - Tonneau (Remove and Install).
2. Remove fastener covers from bed floor assembly
   Note

   14x covers

   

   

   

   

   

3. 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

   

   

   

   

4. 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

   

5. Open powered front trunk
   Note

   Via exterior switch or UI
6. Open charge port door
   Note

   Via UI
7. 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
8. Remove rear underhood apron
   Note

   9x clips

   

   

9. 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

   

   

   

10. 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

    

    

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 there is no high voltage present at the charge port
    Note

    Measure B+ to B-, and B+ to Ground and B - to Ground, Place Alligator clip onto body panel

    

    

    

    

15. Remove bolt securing busbar HV connector lid
    Note

    1x bolt, EP10, 9 Nm

    

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

    2x bolts, 10mm, 9 Nm

    

17. Release HV connector from DC FC header
    Note

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

    

18. 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

    

    

19. Remove fast charger header doubler
    Note

    2x bolts, E10 5 Lobe Torx, 10 Nm

    

    

20. Install fast charger header doubler
    Note

    2x bolts, E10 5 Lobe Torx, 10Nm

    

    

21. 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

    

22. 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

    

23. 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

    

24. Position busbar connector and lower onto HV header
    Note

    Release bungee cord

    

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

    2x bolts, 10mm, 9 Nm

    

26. 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.

    

27. Put on HV insulating gloves and leather over gloves

    

28. 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

    

    

29. Remove leather over gloves and HV insulating gloves
30. Install bolt securing busbar HV connector lid
    Note

    1x bolt, EP10, 9 Nm

    

31. Install bed floor assembly
    Note

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

    

    

    

    

    

32. Install fastener covers onto bed floor assembly
    Note

    14x covers

    

    

    

    

33. 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

    

    

    

34. Install rear underhood apron
    Note

    9x clips, Adjust windshield seal as required

    

    

35. Close powered front trunk
    Note

    Via frunk switch or UI
36. Install the tonneau slats. See Slat System - Tonneau (Remove and Install).
37. Remove vehicle from lift
    Note

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