Correction code 16300106501 16300106502 3.06 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. Raise and support vehicle
   Note

   Set air suspension to "Jack Mode"

   

   

2. Open LH front door
   Note

   Push LH B-pillar door trigger to release

   

   

3. Lower LH front window

   

4. Place the vehicle into Service Mode. See Service Mode.
5. 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

   

   

   

6. Access thermal system routines using the UI
   Note

   Select quick controls > Service mode > Thermal > Actions

   

   

7. Select "Coolant Fill/Drain" through Service UI
   Note

   Select 'Coolant System' to enter coolant circuit screen, Select 'Coolant Fill/Drain' and 'PROC_VCFRONT_X_START-THERMAL-FILL-DRAIN-COOLANT' window will appear, Select 'Run', Verify indicator displays green for Coolant readiness, Thermal Fill Drain routine has a 50 minute time limit
8. Open powered front trunk
   Note

   Via exterior switch or UI

   

   

9. Remove fastener covers from bed floor assembly
   Note

   14x covers

   

   

   

   

   

10. 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

    

    

    

    

11. 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

    

12. Remove rear underhood apron
    Note

    9x clips

    

    

13. 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

    

    

    

14. 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

    

    

15. 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

    

    

16. Remove rear skid plate
    Note

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

    

    

    

    

    

17. Position coolant drain container underneath RH rear of HV battery

    

18. Disconnect rear PT supply and RDU supply hoses
    Note

    2x spring clip, Plug hoses immediately to prevent excess coolant loss, Allow PCS coolant to drain as much as possible before plugging

    

    

19. Release PCS coolant header from ancillary floor
    Note

    2x bolts, EP10, 6Nm

    

20. Remove coolant drain container from underneath vehicle

    

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

    

22. 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.

    

23. 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.

    

24. 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

    

    

    

    

    

    

25. Remove pyro fuse access cover
    Note

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

    

26. Remove primary pyro fuse
    Note

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

    

    

27. Remove secondary pyro fuse
    Note

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

    

    

28. 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

    

    

29. Release 2x4 header assembly
    Note

    4x bolts, 5-lobe 10mm, 6 Nm

    

    

30. Release drive unit connectors from ancillary headers
    Note

    3x connectors, Release blue lock tab, Rotate black latch

    

    

    

31. Remove bolts securing HC-Stak HV Headers for LHRDU, FDU, RHRDU from ancillary flange
    Note

    6x bolts, 5-lobe 10mm, 10 Nm

    

    

32. Remove LHRDU, FDU, RHRDU headers from ancillary flange
    Note

    3x headers, No tools required, inspect header seals, Replace header if damaged

    

    

33. 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

    

    

34. 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

    

    

    

    

    

35. Remove bolt securing busbar HV connector lid
    Note

    1x bolt, EP10, 9 Nm

    

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

    2x bolts, 10mm, 9 Nm

    

37. Release HV connector from DC FC header
    Note

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

    

38. Support HV Busbar assembly
    Note

    Suspend assembly to maintain clearance

    

39. Remove fast charger header doubler
    Note

    2x bolts, E10 5 Lobe Torx, 10 Nm

    

    

40. Release low voltage header
    Note

    2x bolts, EP10, 6 Nm

    

41. 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

    

    

    

42. Remove ancillary cover
    Note

    Use suction cup and maneuver around busbar and tonneau cage

    

    

    

43. Remove DC 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

    

    

    

44. Disconnect PCS MV connector
    Note

    1x connector, 1x zip tie, Slide red lock off of lever, Rotate lever to release connector, Remove zip tie as needed

    

    

45. Release PCS MV harness
    Note

    1x bolt, EP10, 6 Nm, 2x clips, Move aside as needed

    

46. Release MV header
    Note

    4x datums, 1x edge clip, 1x fir tree clip

    

    

    

47. Release HVC connectors
    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

    

    

    

    

    

48. Release BMB passthrough connectors
    Note

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

    

    

    

49. 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

    

    

    

    

50. Remove MV ancillary harness

    

    

51. Release HVC harness from PCS
    Note

    1x connectors, Release connector lock, Depress lever and pull at connector, Do not pull at harness

    

52. Release device cluster busbar fasteners
    Note

    4x bolts, Torx Plus 55, 5Nm + 60 Degrees, Captured bolts with insulated covers

    

    

    

    

53. Remove device cluster assembly fasteners
    Note

    4x bolts, E10 5 Lobe Torx, 6Nm

    

    

    

    

54. 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

    

    

55. Remove bolts securing PCS
    Note

    6x bolts, E10 5-Lobe, 6 Nm, Use E10 5-Lobe socket without magnet, Bolts are captive and will stay attached, Follow fastening order

    

    

56. Remove PCS from ancillary bay
    Note

    1x datum, Maneuver PCS around coolant hoses, Remove plugs as needed

    

    

    

    

    

57. Remove last mile busbar assembly
    Note

    3x bolts, 10mm, 10 Nm, 3x captive bolts, T55, 5 Nm + 60 degrees

    

    

    

58. Install last mile busbar assembly
    Note

    3x bolts, 10mm, 10 Nm, 3x captive bolts, T55, 5 Nm + 60 degrees

    

    

    

59. Install PCS onto ancillary bay
    Note

    1x datum, Maneuver PCS around coolant hoses, Plug coolant connections as needed

    

    

    

    

    

60. Install bolts securing PCS
    Note

    6x bolts, E10 5-Lobe, 6 Nm, Use E10 5-Lobe socket without magnet, Bolts are captive and will stay attached, Follow fastening order

    

    

61. Install 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

    

    

    

62. Secure device cluster assembly fasteners
    Note

    4x bolts, E10 5 Lobe Torx, 6Nm

    

    

    

    

63. Secure device cluster busbar fasteners
    Note

    4x bolts, Torx Plus 55, 5Nm + 60 Degrees, Captured bolts with insulated covers

    

    

    

    

64. 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

    

    

    

    

    

    

    

    

    

65. Secure HVC harness to PCS
    Note

    1x connectors, Secure connector lock

    

66. Poistion MV ancillary harness for install

    

    

67. Secure ACJB LV and HV connectors
    Note

    2x clips, 2x connectors, Secure connector locks

    

    

    

68. 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

    

    

    

69. Secure HVC connectors
    Note

    2x clips, 3x connectors, Release connector locks, Depress levers and pull at connector, Do not pull from harness, Apply sealant to connectors at device cluster if it was present during disassembly

    

    

    

    

    

70. Secure MV header
    Note

    4x datums, 1x edge clip, 1x fir tree clip

    

    

71. Secure PCS MV harness
    Note

    1x bolt, EP10, 6 Nm, 2x clips

    

72. Connect PCS MV connector
    Note

    1x connector, 1x zip tie, Install zip tie onto ECPA latch, PCS header not datumed, Ensure correct orientation and polarity of connection, Harness color red for LV+ and black for LV-, Swing down locking lever, Slide lock fully to engage on top of lever

    

    

    

    

73. 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

    

    

    

    

74. Install ancillary cover
    Note

    Use suction cup and maneuver around busbar and tonneau cage

    

    

    

    

75. 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

    

    

    

76. Secure low voltage header
    Note

    2x bolts, EP10, 6 Nm

    

77. Secure fast charger header doubler
    Note

    2x bolts, E10 5 Lobe Torx, 10Nm

    

    

78. 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

    

79. 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

    

80. 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

    

81. Position busbar connector and lower onto HV header
    Note

    Release bungee cord

    

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

    2x bolts, 10mm, 9 Nm

    

83. 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

    

    

84. Install bolt securing busbar HV connector lid
    Note

    1x bolt, EP10, 9 Nm

    

85. Remove leather over gloves and HV insulating gloves

    

86. Connect Ancillary bay MV connector
    Note

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

    

    

    

    

    

87. 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

    

    

88. Secure PCS coolant header to ancillary floor
    Note

    2x bolts, EP10, 6Nm

    

89. Position coolant drain container underneath RH rear of HV battery

    

90. Remove one PCS coolant header plugs & connect leak test adapters
    Note

    2x spring clips, Leave coolant plugs in supply and return lines, Secure NW22 plug to either coolant header port (Item 6 of kit), Combine NW18 Male testing Couple (Item 5 of kit) to Adapter NW18 180° (Item 1 of kit) and secure to other coolant header port

    

    

    

    

    

91. Attach coolant pressure tester to pressure fitting adapter
    Note

    Confirm hose is securely screwed tight

    

92. Attach coolant pressure tester to compressed air line
    Note

    Make sure valves are closed on pressure regulator

    

    

93. Open the regulator valve then slowly adjust regulator to 50 psi
    Note

    Use caution as coolant may spill, Make sure to wear safety glasses

    

    

94. Open 2nd valve slowly
    Note

    Slowly open valve on pressure regulator and allow pressure to reach specification

    

95. Close the valve and let pressure settle
    Note

    Wait 2 minutes for pressure to settle, Record the reading

    

96. Set timer for 2 minutes and select start
    Note

    Once timer is complete, select Stop Reset

    

97. Perform the coolant pressure leak test
    Note

    Wait for another 4 minutes and record the reading. Max delta 0.35 psi. Check coolant hose to see if it is fully seated or not if pressure test fails

    

98. Close both valves

    

99. Remove coolant pressure tester from pressure fitting adapter

    

100. Remove coolant pressure tester adapter from PCS coolant header

     

101. Connect rear PT supply and RDU supply hoses
     Note

     2x spring clip, Make sure the locking tabs are fully seated, Perform push-pull-push test

     

102. Remove coolant drain container from underneath vehicle

     

103. 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.

     

104. Put on HV insulating gloves and leather over gloves

     

105. Install LHRDU, FDU, RHRDU headers to ancillary flange
     Note

     3x headers, No tools required, inspect header seals, Replace header if damaged

     

     

106. Secure bolts to HC-Stak HV Headers for LHRDU, FDU, RHRDU to ancillary flange
     Note

     6x bolts, 5-lobe 10mm, 10 Nm

     

     

107. Secure 2x4 header assembly
     Note

     4x bolts, 5-lobe 10mm, 6 Nm, Confirm alignment of assembly with fastener openings

     

     

     

108. Secure connectors at 2x4 header (AC compressor and Inductive Charger headers)
     Note

     2x connectors, Fully engage red lock tab

     

     

109. Secure drive unit connectors to ancillary headers
     Note

     3x connectors, Rotate black latch, Ensure blue locking tab is fully engaged

     

     

     

110. Install secondary pyro fuse
     Note

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

     

     

111. Install primary pyro fuse
     Note

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

     

     

112. 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

     

     

113. Remove leather over gloves and HV insulating gloves

     

114. 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

     

     

115. Install Mid-aero shield
     Note

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

     

     

     

     

     

116. 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

     

     

117. Remove coolant bottle cap

     

118. Install coolant reservoir adaptor cap onto coolant bottle assembly

     

     

     

119. Place empty coolant container into front storage area
     Note

     If frunk is not installed take caution, CFM fan shroud assembly cannot support a full coolant container, Ensure overflow container is empty, Place fender cover over FEM and front fascia

     

120. Fill container with at least 15L of coolant

     

121. Place filled coolant container onto coolant drain & fill cart
     Note

     Do not place container with 15L of coolant on top of CFM fan shroud, Position cart as close as possible to front of vehicle

     

122. Setup coolant refill tool
     Note

     Verify all valves on refill tool are in the closed position, See image for clarity

     

     

123. Install vacuum refill hose to refill cap on coolant bottle
     Note

     Perform push-pull-push test to verify hose is fully installed

     

124. Position overflow hose into empty container

     

125. Place refill hose inside filled coolant container
     Note

     Make sure hose end is fully submerged into coolant

     

126. Connect shop air supply to coolant refill tool
     Note

     If not already done, Verify refill valve is set to off

     

127. Open air inlet valve to draw a vacuum, Once gauge stabilizes, Fully close valve
     Note

     Gauge stabilizes roughly (60-70 cmHg), Vacuum should not drop after the valves are closed

     

     

128. Slowly open the refill valve to allow coolant to be drawn into the system
     Note

     Make sure hose end of refill hose is fully submerged during entire process

     

129. Once the gauge reads zero, close the coolant refill valve

     

     

130. Remove shop air supply to coolant refill tool
     Note

     If not already done, Verify refill valve is set to off

     

131. Remove coolant refill hose from coolant container

     

132. Remove coolant overflow hose from coolant container

     

133. Remove vacuum refill hose from refill cap on coolant bottle

     

134. Remove vacuum refill cap from coolant bottle assembly

     

135. Remove coolant refill tool from vehicle
     Note

     Move coolant drain & fill cart away from vehicle

     

     

136. Remove coolant container from inside underhood area

     

137. 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

     

     

     

138. Select "Stop Thermal Fill Drain" through UI
     Note

     Allow routine to complete, ensure routine is successful
139. Select "Start Coolant Air Purge" using the UI
     Note

     Touch time only, wait until coolant pumps stop running (audible noise), Routine Passed will appear, but pumps will run for 10 minutes, If you start next another routine during this time it will fail, Make sure vehicle is not in "Drive", Routine is still running despite the completed message, Speeds can be monitored in garage under PT Thermal tab, Idle speed = ~1500 RPM, Test will vary speeds from 3500-6500 RPM and actuate valves between SERIES and PARALLEL, Putting vehicle into "Drive" will stop this routine, If speeds hover at 7000 RPM, this indicates the pumps are air locked, perform a vacuum fill, Continue to add coolant and purge until the coolant level reaches between the NOM and MAX Lines on the bottle

     

     

     

140. Inspect coolant level and top off as necessary
     Note

     Ensure that the fluid level is at the Max line, Top off fluid as required

     

141. Install coolant bottle cap

     

142. Install rear underhood apron
     Note

     9x clips, Adjust windshield seal as required

     

     

143. Close powered front trunk
     Note

     Via exterior switch or UI

     

144. Install bed floor assembly
     Note

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

     

     

     

     

     

145. Install fastener covers onto bed floor assembly
     Note

     14x covers

     

     

     

     

146. Perform Thermal Performance through the UI
     Note

     Select Thermal > Actions > Test Thermal Performance, click Run, close once routine is completed, if thermal test fails follow toolbox article 206000

     

     

     

     

147. Exit Service Mode. See Service Mode.
148. Raise LH front window

     

149. Close LH front door

     

150. Remove vehicle from lift
     Note

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