Correction code NEW 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.

1. Raise and support vehicle
   Note

   Set air suspension to "Jack Mode"

   

   

2. Unlock vehicle gateway
   Note

   After vehicle has been put into "Service Mode", place keycard on center console to turn on drive rails, hold down the brake pedal, while keep pressing right hand signal button simultaneously for at least 10 seconds, "GTW UNLOCKING" should pop up on the UI right next to the VIN during these 10 seconds, once gateway is unlocked "GTW UNLOCKED 5400" will be displayed on the UI next to the VIN, the gateway will remain unlocked for 90 minutes, follow steps on Toolbox article #5582900 for any additional information

   

   

   

3. Open powered front trunk
   Note

   Via exterior switch or UI

   

   

4. Open tailgate
   Note

   Press button to release

   

5. Remove fastener covers from bed floor assembly
   Note

   14x covers

   

   

   

   

   

6. Remove bed floor assembly
   Note

   10x short bolts, 15mm, 56 Nm, 2x long bolts, 15mm, 46Nm, Lift front edge with trim tool then remove panel, Recommend assistance

   

   

   

   

7. Power down vehicle via UI
   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 FRL connector then disconnect 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. Raise vehicle fully
    Note

    Set to a comfortable working height, Lower to locks, Ensure locks engage on both sides to prevent tilting

    

    

12. Remove rear skid plate
    Note

    6x clips, 3x bolts, 15mm, 42 Nm, 5x bolts, 13mm, 28 Nm, 2x bolts, 10mm, 6 Nm

    

    

    

    

    

13. Remove all items from pockets and ensure not wearing metal items

    

14. Inspect HV insulating gloves
    Note

    Check gloves for damage prior to use, Refer to service document TN-15-92-003

    

15. Put on HV insulating gloves and leather over gloves

    

16. 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

    

    

    

    

    

    

17. 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

    

    

18. Remove pyro fuse access cover
    Note

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

    

19. Remove primary pyro fuse
    Note

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

    

    

20. Remove secondary pyro fuse
    Note

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

    

    

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. 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

    

    

    

    

    

23. Remove bolt securing busbar HV connector lid
    Note

    1x bolt, EP10, 9 Nm

    

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

    2x bolts, 10mm, 9 Nm

    

25. Release HV connector from DC FC header
    Note

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

    

26. Support HV Busbar assembly
    Note

    Suspend assembly to maintain clearance

    

27. Remove fast charger header doubler
    Note

    2x bolts, E10 5 Lobe Torx, 10 Nm

    

    

28. Release low voltage header
    Note

    2x bolts, EP10, 6 Nm

    

29. 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

    

    

    

30. Remove ancillary cover
    Note

    Use suction cup and maneuver around busbar and tonneau cage

    

    

    

31. Remove ACJB to PCS HV jumper harness
    Note

    2x connectors, Release locking tab and pull connector out of respective header, Do not pull on harness

    

    

    

32. Release ACJB LV connector & ACJB to device cluster HV connector
    Note

    2x connectors, Release connector locks, Depress levers and pull at connectors, Do not pull at harness

    

    

33. Release ancillary connectors to center console outlet and bed outlet
    Note

    2x connectors, Release locking tabs, Slide locks to release

    

    

34. Release ACJB header fastener
    Note

    1x bolt, T25, Torque??

    

    

    

35. Release ACJB fasteners
    Note

    6x bolts, E10 5 Lobe Torx, 6Nm

    

    

36. Release ACJB from ancillary tray
    Note

    2x clips, 2x datums, Release clips at headers, Slide ACJB inboard on datums

    

    

37. Remove ACJB from ancillary tray
    Note

    Lift over and out of PCS once headers clear outboard side of ancillary tray

    

    

38. Install ACJB onto ancillary tray
    Note

    Align headers and slide openings to datums in ancillary tray

    

    

    

39. Slide ACJB into ancillary tray until header clips are fully engaged
    Note

    Ensure all fastener holes are aligned

    

    

    

40. Secure ACJB fasteners
    Note

    6x bolts, E10 5 Lobe Torx, 6Nm

    

    

41. Secure ACJB header fastener
    Note

    1x bolt, T25, Torque??

    

    

    

42. Secure ancillary connectors to center console outlet and bed outlet
    Note

    2x connectors, Slide locks to fully engage, Secure locking tabs

    

    

43. Install ACJB to PCS HV jumper harness
    Note

    2x connectors, Secure at ACJB first then fold harness over to PCS, Secure locking tab on both connectors

    

    

    

    

44. Secure ACJB LV harness connector & ACJB HV harness to device cluster connector
    Note

    2x connectors, Secure connector locks

    

    

45. Install ancillary cover
    Note

    Use suction cup and maneuver around busbar and tonneau cage

    

    

    

    

46. Secure fasteners of 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

    

    

    

47. Secure low voltage header
    Note

    2x bolts, EP10, 6 Nm

    

48. Secure fast charger header doubler
    Note

    2x bolts, E10 5 Lobe Torx, 10Nm

    

    

49. 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

    

50. 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

    

51. 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

    

52. Position busbar connector and lower onto HV header
    Note

    Release bungee cord

    

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

    2x bolts, 10mm, 9 Nm

    

54. 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

    

    

55. Install bolt securing busbar HV connector lid
    Note

    1x bolt, EP10, 9 Nm

    

56. Remove leather over gloves and HV insulating gloves
57. Connect Ancillary bay MV connector
    Note

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

    

    

    

    

    

58. Raise vehicle fully

    

59. Remove all items from pockets and ensure not wearing metal items
60. Inspect HV insulating gloves
    Note

    Check gloves for damage prior to use, Refer to service document TN-15-92-003

    

61. Put on HV insulating gloves and leather over gloves

    

62. Clean mating surface of the pyro
    Note

    Use a non-conductive plastic tool to clean the busbar side, Allow 1 minute for IPA to fully dry, Do not use any other types of cleaner

    

    

    

63. Install secondary pyro fuse
    Note

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

    

    

64. Install primary pyro fuse
    Note

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

    

    

65. 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

    

    

66. Remove leather over gloves and HV insulating gloves
67. 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

    

    

68. Install Mid-aero shield
    Note

    6x clips, 3x bolts, 15mm, 70 Nm, 3x bolts, 13mm, 28 Nm, 2x bolts, 10mm, 6 Nm

    

    

    

    

    

69. 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

    

    

70. Connect FRL connector then connect 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

    

    

    

71. Install rear underhood apron
    Note

    9x clips, Adjust windshield seal as required

    

    

72. Close powered front trunk
    Note

    Via exterior switch or UI

    

73. Perform software reinstall
    Note

    Via UI > Service Mode > Software Reinstall > CAN ECU > Reinstall, Reinstall will begin immediately, Once firmware redeploy is complete, Verify release notes are present via UI

    

    

    

74. Install bed floor assembly
    Note

    10x short bolts, 15mm, 56 Nm, 2x long bolts, 15mm, 46Nm, Recommend assistance

    

    

    

    

    

75. Install fastener covers onto bed floor assembly
    Note

    14x covers

    

    

    

    

76. Close tailgate

    

77. Run ODIN routine PROC_ICE_X_EXIT-SERVICE-MODEvia Toolbox: (link)
78. Remove vehicle from lift
    Note

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