2025-12-30

HV Battery (AWD) (Remove and Replace)

Correction code 16010202 FRT 8.05 NOTE: Unless otherwise explicitly stated in the procedure, the above correction code and FRT 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. To provide feedback on FRT values, email ServiceManualFeedback@tesla.com. NOTE: See Personal Protection to make sure wearing proper PPE when performing the below procedure. NOTE: See Ergonomic Precautions for safe and healthy working practices.

  • 2025-10-09: Rearranged steps for better flow.
  • 2025-08-11: Added images for battery alignment rod holes.
  • 2025-04-16: Moved battery alignment rod step before installing front exterior mounting bolts.
  • 2025-03-27: Added note for possible variation in fastener size depending on vehicle. Added note to release lower B-pillar trim if needed.
  • 2025-01-30: Added step to install updated charge port busbar DCA-side header for older vehicles receiving CPIL-enabled replacement HV packs.
  • 2025-01-23: Added step to determine if HV battery parameters are within safe limits before removing the pyro disconnect. Added pyro disconnect removal step.
  • 2025-01-23: Updated all HV battery support table images.
  • 2025-01-14: Updated entire procedure to the latest validation.
  • 2024-12-03: Updated multiple steps to include releasing/installing harness clips.
  • 2024-11-22: Added warning to NOT skip steps to remove the tonneau slats.
  • 2024-10-31: Added HV battery discharge steps.
  • 2024-09-18: Updated to latest time study.
  • 2024-09-12: Added step to connect MV maintainer.
  • 2024-08-09: Added PN of anti-abrasion tape.
  • 2024-06-26: Updated steps to latest time study.
Warning IconA warning icon, calling your attention to a possibly risky situation
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 IconA warning icon, calling your attention to a possibly risky situation
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.
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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.
Special tools required for this procedure:
  • 1134523-00-B - Battery Alignment Rods
  • 1065131-00-A - Battery Coolant Drain Kit
  • 1135762-00-A - Coolant Hose Plug Kit
  • 1080568-00-A - Fluid Catcher
  • 1076927-00-A - Hioki tester
  • 1020566-00-F - HV Battery Table
  • 1076928-00-A - Test Probes - Hioki 9461
  • 1936724-00-A - Universal Lift Pad adapters
  • 1050448-00-B - Vacuum Refill Tool
  • 1479505-00-A - Vacuum Fill Adapter
  • 113343-80-A - Battery Drain Adapter
  • 1879451-99-A - LV ABRASION STICKER,XM,HVB,CTSB

Discharge

WARNING: To conform with local laws, High Voltage Lithium Batteries must be discharged before packing for shipment. Additionally, HV batteries must be discharged before being put into storage. HV batteries to be shipped must have a State of Charge (SoC) of less than 25% or 45%, depending on the region. If the method of shipment is unknown or uncertain, or the battery is to be stored, it is recommended to discharge the HV battery to less than 25%.

WARNING: After discharge, wait 20 minutes and verify that the SoC is less than the targeted value. This waiting period allows the open circuit voltage (OCV) to settle, which is critical for accurate measurements. Continue discharging if the SoC does not meet the required level.

Make sure to collect all HV battery shipping data using the HV Battery Communication Tool, preferably before removing the HV battery from the vehicle.

WARNING: Do not ship or store an HV battery that has a loss of high voltage isolation. Verify HV battery isolation before packing for shipment or storage. Use the HV Battery Communication Tool, described in Toolbox article #41977 or Customer Document CD-21-16-003, to determine if the HV battery parameters are within safe limits for shipment or storage.
Informational PurposesAn informational icon, calling your attention
Note
If possible, perform the discharge procedure and collect HV battery shipping data before HV battery removal. This method requires less time and user interaction than to use the Battery Discharge Tool after the battery has been removed. The Battery Discharge Tool can only be used by certified technicians..
Informational PurposesAn informational icon, calling your attention
Note
The steps of the discharge procedure are mostly touch time, and can be performed by the Service Advisors/Front of House team as well as Service Technicians..
  1. Enable Service Mode Plus. See Toolbox 3 (Connect and Disconnect).
  2. Identify the vehicle's current SOC Max: In the Service Mode Plus menu, touch High Voltage > HV Battery, and then touch the large HV battery diagram to display the HV Battery information window.
    • If the SOC Max is less than the SOC shipping threshold, skip to step 6 of this sub-procedure.
    • If the SOC Max is greater than the SOC shipping threshold, continue to the next step.
  3. Move the vehicle to a location where the battery can be safely discharged unattended.
  4. In the Service Mode Plus menu, touch High Voltage > HV Battery.
  5. In the Tools section, touch Start HV Discharge, and then in the window that opens, touch Run.
    Informational PurposesAn informational icon, calling your attention
    Note
    The discharge routine starts and will automatically stop when the SOC Max value for surface transport has been attained.
  6. After discharge is complete, use the HV Battery Communication Tool to collect HV battery shipping data, and then move the vehicle to the service bay.

Remove

  1. Remove the HV battery from the vehicle. See HV Battery (AWD) (Remove and Install).
  2. Secure PT Flush adapter to PCS inlet hose coupling
    Informational PurposesAn informational icon, calling your attention
    Note
    Remove plugs as required, Verify fully seated, Perform push-pull-push test
  3. Secure coolant cart flush hose to regulator and PT Flush adapter
    Informational PurposesAn informational icon, calling your attention
    Note
    Verify regulator valve is closed, Pressure regulator is not adjustable (set at 20 psi)
  4. Secure PCS Drain adapter to PCS outlet using male-to-male adapter
    Informational PurposesAn informational icon, calling your attention
    Note
    Verify valve is closed, Remove plug as required, Verify fully seated, Perform push-pull-push test
  5. Secure coolant cart drain hose to PCS drain adapter and coolant drain container
  6. Open valve on PCS Drain adapter
  7. Connect shop air to regulator
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure regulator valve is closed prior to connecting shop air
  8. Slowly open valve on pressure regulator and allow coolant to drain out of HV battery
    Informational PurposesAn informational icon, calling your attention
    Note
    Allow coolant to drain
  9. Close valve on pressure regulator once no more coolant is draining
  10. Close valve on PCS Drain adapter
  11. Remove cart drain hose from PCS Drain adapter
  12. Remove PCS Drain adapter from PCS outlet
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip
  13. Remove cart flush hose from PT Flush adapter
  14. Remove PT Flush adapter from PCS inlet coupling
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip
  15. Attach coolant cart flush hose to HV battery
    Informational PurposesAn informational icon, calling your attention
    Note
    Remove plugs as required, Verify fully seated, Perform push-pull-push test, Verify regulator valve is closed, Pressure regulator is not adjustable (set at 20 psi), Hose is still attached to cart at this point
  16. Attach PCS drain adapter to HV battery hose coupling using male-to-male adapter
    Informational PurposesAn informational icon, calling your attention
    Note
    Verify valve is closed, Verify fully seated, Remove plugs as required, Perform push-pull-push test, Connect to coolant drain
  17. Open valve on P2 Battery Drain adapter
  18. Slowly open valve on pressure regulator and allow coolant to drain out of HV battery
    Informational PurposesAn informational icon, calling your attention
    Note
    Allow coolant to drain
  19. Close valve on pressure regulator once no more coolant is draining
  20. Disconnect compressed air from coolant pressure tester
  21. Close valve on P2 Battery drain adapter
  22. Remove cart drain hose and PCS drain adapter from HV battery
  23. Remove cart flush hose and PCS flush adapter from battery
  24. Remove RH pressurized pack air line
    Informational PurposesAn informational icon, calling your attention
    Note
    2x clips, 1x voss fitting, 12mm, 8 Nm
  25. Remove FDU HV harness
    Informational PurposesAn informational icon, calling your attention
    Note
    12x bolts, 10mm, 11 Nm
  26. Remove powertrain hose bundle
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip, 6x clips, Release hose from PCS fitting
  27. Use the HV Battery Communication Tool, described in Toolbox article #41977 or Customer Document CD-21-16-003, to determine if the HV battery parameters are within safe limits before proceeding.
  28. Remove the pyro disconnect prior to shipping the HV battery. See Pyro Disconnect (Remove and Install).
  29. Attach HV battery H-frame to gantry and raise into position
  30. Secure the P2 battery sling adapter to H-frame
    Informational PurposesAn informational icon, calling your attention
    Note
    4x anchor hooks, Install hooks, Verify anchor hooks are fully tightened and secured, Be aware and do not install anchors hooks in a manner which will cause the adapter sling to bind or twist
  31. Remove top housing from new HV battery crate
    Informational PurposesAn informational icon, calling your attention
    Note
    Recommend assistance
  32. Position gantry over HV battery crate
    Informational PurposesAn informational icon, calling your attention
    Note
    Recommend assistance
  33. Lower H-frame to HV battery crate
  34. Secure P2 sling adapter to HV battery
    Informational PurposesAn informational icon, calling your attention
    Note
    6x locking joints, The hoist is color coded and will come with instructions, Verify all the locking joints are fully secured, Perform push and pull test, If not properly secured the top pin will be recessed, Take care to secure properly and safely
  35. Lift new HV battery out of crate
  36. Move gantry away from HV battery crate
    Informational PurposesAn informational icon, calling your attention
    Note
    Recommend assistance
  37. Position unused HV battery table under gantry
  38. Lower HV battery onto battery table
  39. Release P2 battery sling adapter from HV battery
    Informational PurposesAn informational icon, calling your attention
    Note
    6x locking joints, Push down on top pin to release
  40. Remove HV battery and table from under gantry
    Informational PurposesAn informational icon, calling your attention
    Note
    Recommend assistance
  41. Position old HV battery and table under gantry
    Informational PurposesAn informational icon, calling your attention
    Note
    Recommend assistance
  42. Secure P2 sling adapter to HV battery
    Informational PurposesAn informational icon, calling your attention
    Note
    6x locking joints, The hoist is color coded and will come with instructions, Verify all the locking joints are fully secured, Perform push and pull test, If not properly secured the top pin will be recessed, Take care to secure properly and safely
  43. Raise HV battery off of battery table
  44. Remove empty HV battery table from under gantry
  45. Position gantry over HV battery crate
    Informational PurposesAn informational icon, calling your attention
    Note
    Recommend assistance
  46. Lower old HV battery into crate
    Informational PurposesAn informational icon, calling your attention
    Note
    Recommend assistance, Use caution to align HV battery into crate and do not damage the battery
  47. Release P2 battery sling adapter from HV battery
    Informational PurposesAn informational icon, calling your attention
    Note
    6x locking joints, Push down on top pin to release
  48. Raise gantry and H-frame from crate
  49. Secure top housing onto HV battery crate
    Informational PurposesAn informational icon, calling your attention
    Note
    Recommend assistance, Adhere to proper MRB process
  50. Return gantry to position and remove HV battery H-frame from gantry

Install

  1. If replacing HV battery pack PN 1783970-TX-E or earlier with 1783970-TX-F or later, replace the DCA-side HV header on the charge port busbar. See HV Connector Header, Plug (Remove and Install).
    Informational PurposesAn informational icon, calling your attention
    Note
    Replacement HV battery packs 1783970-TX-F and later have Charge Port Interlock Loop (CPIL) circuitry. Older vehicles require this updated charge port busbar DCA-side header in order to connect to the CPIL circuitry and enable DC charging.
    Informational PurposesAn informational icon, calling your attention
    Note
    Do not rely on the appearance of the DCA DC input header to determine whether the replacement HV battery pack has CPIL circuitry, as it is possible that some DCAs have DC input headers that have the CPIL connection, but have a High Voltage Controller (HVC) that does not support CPIL. Look only at replacement pack's PN to determine whether the pack has CPIL circuitry (1783970-TX-F and later).
  2. Apply backbone harness abrasion protection
    Informational PurposesAn informational icon, calling your attention
    Note
    6x abrasion tape strips, Apply narrow patch to forwardmost position between should bracket ribs, Refer to image for clarity, Skip step if abrasion protection already present and installed correctly, Wide patch dimensions: 50mm wide, 150mm long, Narrow patch dimensions: 25.4mm wide, 235mm long
  3. Install powertrain hose bundle
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip, 6x clips, Perform a push-pull-push test to ensure hose is fully seated
  4. Install FDU HV harness
    Informational PurposesAn informational icon, calling your attention
    Note
    12x bolts, 10mm, 11 Nm
  5. Install RH pressurized pack air line
    Informational PurposesAn informational icon, calling your attention
    Note
    2x clips, 1x voss fitting, 12mm, 8 Nm
  6. Follow HV Battery (AWD) (Remove and Install). Stop when MV power is reconnected.
  7. In Service Mode Plus, select High Voltage > Procedures
  8. Select HV Battery Replacement Procedure
  9. Select Software Reinstall.
  10. Select High Voltage Battery Replacement Routine.
  11. Reinstall all components that were removed for battery replacement. See HV Battery (AWD) (Remove and Install).