Correction code 1630010091 1630010092 FRT 3.42 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.

1. Raise and support the vehicle. See Raise Vehicle - 2 Post Lift.
2. Open the LH front door and lower the LH front window.
3. Place the vehicle into Service Mode. See Service Mode.
4. Unlock the vehicle Gateway. See Gateway (Unlock).
5. Remove the tonneau slats. See Slat System - Tonneau (Remove and Install).
6. Remove bed floor assembly
   Note

   10x bolts, 15mm, 56 Nm, 4x anchors, Open anchors as needed, Lift front edge with trim tool then remove panel, Recommend assistance

   

   

   

7. Remove fasteners securing RH tonneau NVH barrier
   Note

   6x bolts, T25, 5 Nm, Vehicles built before April 2024 will have 1-piece NVH cover, 5x bolts, 8mm, 5 Nm, Vehicles built after April 2024 will have updated 1-piece NVH cover, 9x bolts, 4mm Allen, 5 Nm, Vehicles built after October 2024 will have 2-piece NVH cover

   

   

   

8. Remove RH tonneau NVH barrier
   Note

   Vehicles built before April 2024 will have 1-piece NVH cover, Vehicles built after April 2024 will have updated 1-piece NVH cover, Vehicles built after October 2024 will have 2-piece NVH cover, Maneuver around bed wall then remove

   

   

   

   

   

   

9. Remove fasteners securing LH tonneau NVH barrier
   Note

   5x bolts, T25, 5 Nm, Vehicles built before April 2024 will have 1-piece NVH cover, 5x bolts, 8mm, 5 Nm, Vehicles built after April 2024 will have updated 1-piece NVH cover, 9x bolts, 4mm Allen, 5 Nm, Vehicles built after October 2024 will have 2-piece NVH cover

   

   

   

10. Remove LH tonneau NVH barrier
    Note

    Vehicles built before April 2024 will have 1-piece NVH cover, Vehicles built after April 2024 will have updated 1-piece NVH cover, Vehicles built after October 2024 will have 2-piece NVH cover, Maneuver around bed wall then remove

    

    

    

    

    

    

11. Remove tonneau coverbox cross supports
    Note

    8x screws, T25, 5 Nm

    

    

12. 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

    

13. Open powered front trunk
    Note

    Via exterior switch or UI

    

    

14. 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

    

15. Remove rear underhood apron
    Note

    9x clips

    

    

16. 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

    

    

    

17. 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

    

    

18. Release pressurized pack air line to Ancillary
    Note

    1x connector, Do not release air line to reservoir, Rapid loss of pressure will result if wrong air line is released.

    

19. Remove VOSS fitting from pressurized pack air line to Ancillary
    Note

    1x VOSS fitting, Slide threaded section back, Remove the collet, Then slide threaded section off of air line, Discard after removal

    

    

20. Release pressurized pack valve block from air suspension reservoir
    Note

    1x bolt, 10mm, 5 Nm, 1x connector, 1x clip, 1x zip tie, Release lock before connector disengagement, Cut zip tie at reservoir/ancillary air line bundle, Release harness clip at bracket

    

    

21. Release air suspension valve block
    Note

    3x rubber grommets, Rotate clockwise until top 2 rubber feet have released from bracket, Pull upwards at 45 degree angle to release bottom rubber foot from bracket, Leave all air lines and connections secured and set assembly aside

    

    

    

22. Release air suspension reservoir
    Note

    2x nuts, 13mm, 33 Nm, 2x fir tree clips

    

    

23. Place air suspension reservoir in service position then install Ancillary Access Bench
    Note

    Raise and swing air suspension reservoir to the side of the bed, Place Ancillary Access Bench onto rear casting ensuring no air lines or harnesses are being pinched

    

    

    

24. Remove mid aeroshield. See Skid Plate - Rear (Remove and Install).
25. Disconnect pressurized pack lines
    Note

    2x VOSS fittings, 12mm, 8Nm, Discard and replace

    

26. Remove VOSS fitting from pressurized pack air lines
    Note

    2x VOSS fitting, Slide threaded section back, Remove the collet, Then slide threaded section off of air line, Discard after removal

    

    

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

    

28. 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. https://service.teslamotors.com/documents?model=&keys=TN-15-92-003&vehicle_system=&sort_by=field_date_submitted&sort_order=DESC

    

29. Put on HV insulating gloves and leather over gloves

    

30. 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

    

    

    

    

    

    

31. 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

    

    

32. Remove Pyro Fuse Access cover
    Note

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

    

33. Remove primary pyro fuse
    Note

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

    

    

34. Remove secondary pyro fuse
    Note

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

    

    

35. 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
36. 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

    

    

    

    

    

37. Remove bolt securing busbar HV connector lid
    Note

    1x bolt, EP10, 9 Nm

    

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

    2x bolts, 10mm, 9 Nm

    

39. Release HV connector from DC FC header
    Note

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

    

40. Support HV Busbar assembly
    Note

    Suspend assembly to maintain clearance

    

41. Remove fast charger header doubler
    Note

    2x bolts, E10 5 Lobe Torx, 10 Nm

    

    

42. Release low voltage header
    Note

    2x bolts, 10mm, 6 Nm

    

43. 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

    

    

    

44. Remove ancillary cover
    Note

    Use suction cup and maneuver around busbar and tonneau cage

    

    

    

45. 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

    

    

    

46. 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

    

    

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

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

    

    

48. Release ACJB fasteners
    Note

    6x bolts, E10 5 Lobe Torx, 6Nm

    

    

49. Release ACJB from ancillary tray
    Note

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

    

    

50. Remove ACJB from ancillary tray
    Note

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

    

    

51. Install ACJB to ancillary tray
    Note

    Align headers and slide openings to datums in ancillary tray

    

    

    

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

    Ensure all fastener holes are aligned

    

    

    

53. Secure ACJB fasteners
    Note

    6x bolts, E10 5 Lobe Torx, 6Nm

    

    

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

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

    

    

55. 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

    

    

    

    

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

    2x connectors, Secure connector locks

    

    

57. Install ancillary cover
    Note

    Use suction cup and maneuver around busbar and tonneau cage

    

    

    

    

58. 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

    

    

    

59. Secure low voltage header
    Note

    2x bolts, 10mm, 6 Nm

    

60. Secure fast charger header doubler
    Note

    2x bolts, E10 5 Lobe Torx, 10Nm

    

    

61. 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

    

62. 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

    

63. 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

    

64. Position busbar connector and lower onto HV header
    Note

    Release bungee cord

    

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

    2x bolts, 10mm, 9 Nm

    

66. 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

    

    

67. Install bolt securing busbar HV connector lid
    Note

    1x bolt, EP10, 9 Nm

    

68. Remove leather over gloves and HV insulating gloves
69. Connect Ancillary bay MV connector
    Note

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

    

    

    

    

    

70. Secure tonneau coverbox cross supports
    Note

    8x screws, T25, 5 Nm, Supports install in the same direction of the fasteners

    

    

71. Position LH tonneau NVH barrier
    Note

    Vehicles built before April 2024 will have 1-piece NVH cover, Vehicles built after April 2024 will have updated 1-piece NVH cover, Vehicles built after October 2024 will have 2-piece NVH cover, Maneuver around bed wall then position

    

    

    

    

    

    

72. Install fasteners securing LH tonneau NVH barrier
    Note

    5x bolts, T25, 5 Nm, Vehicles built before April 2024 will have 1-piece NVH cover, 5x bolts, 8mm, 5 Nm, Vehicles built after April 2024 will have updated 1-piece NVH cover, 9x bolts, 4mm Allen, 5 Nm, Vehicles built after October 2024 will have 2-piece NVH cover

    

    

    

73. Position RH tonneau NVH barrier
    Note

    Vehicles built before April 2024 will have 1-piece NVH cover, Vehicles built after April 2024 will have updated 1-piece NVH cover, Vehicles built after October 2024 will have 2-piece NVH cover, Maneuver around bed wall then position

    

    

    

    

    

    

74. Install fasteners securing RH tonneau NVH barrier
    Note

    6x bolts, T25, 5 Nm, Vehicles built before April 2024 will have 1-piece NVH cover, 5x bolts, 8mm, 5 Nm, Vehicles built after April 2024 will have updated 1-piece NVH cover, 9x bolts, 4mm Allen, 5 Nm, Vehicles built after October 2024 will have 2-piece NVH cover

    

    

    

75. Remove Ancillary Access Bench then place air suspension reservoir into position for installation
    Note

    Ensure air lines are not twisted, Ensure no harnesses are caught

    

    

    

76. Secure air suspension reservoir
    Note

    2x nuts, 13mm, 33 Nm, 2x fir tree clips

    

    

77. Secure air suspension valve block
    Note

    3x rubber grommets, Rotate counter-clockwise until top 2 rubber feet are secured onto bracket, Push downwards at 45 degree angle to secure bottom rubber foot into bracket, Position air lines and connections into place for installation

    

    

    

78. Install new VOSS air fitting to pressurized pack valve block at ANC circuit
    Note

    1x VOSS fitting, 12mm, 8 Nm, Do not remove VOSS plastic plug until pressurized pack line is installed

    

    

79. Secure pressurized pack air line from Ancillary to valve block
    Note

    1x line, Remove plastic cap from VOSS fittings, Press air lines into fitting until mark aligns with top of fitting, Verify line is properly secured by performing push and pull test

    

    

80. Secure pressurized pack valve block to air suspension reservoir
    Note

    1x bolt, 10mm, 5 Nm, 1x connector, 1x clip, 1x zip tie, Secure reservoir and ancillary air lines at white marked sections

    

    

81. Install bed floor assembly
    Note

    10x bolts, 15mm, 56 Nm, 4x anchors, Open and close anchors as needed, Recommend assistance

    

    

    

82. Raise vehicle fully
83. Remove all items from pockets and ensure not wearing metal items

    

84. 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. https://service.teslamotors.com/documents?model=&keys=TN-15-92-003&vehicle_system=&sort_by=field_date_submitted&sort_order=DESC

    

85. Put on HV insulating gloves and leather over gloves

    

86. 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

    

    

    

87. Install secondary pyro fuse
    Note

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

    

    

88. Install primary pyro fuse
    Note

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

    

    

89. 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

    

    

    

90. Remove leather over gloves and HV insulating gloves
91. Install Pyro Fuse Access cover
    Note

    4x bolts, E-Torx 5 lobe, 10 Nm, Ensure seal is fully seated and undamaged

    

    

92. Install pressurized pack lines
    Note

    2x VOSS fittings, 12mm, 8 Nm, Remove plastic caps from VOSS fittings, Install new VOSS fittings if re-using fuse cover, Press air lines into fitting until mark aligns with top of fitting, Verify line is properly secured by performing push and pull test

    

    

    

93. Install the mid aeroshield. See Skid Plate - Rear (Remove and Install).
94. 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
95. Reconnect MV power. See Disconnect MV Power (Modify).
96. Install the rear underhood apron. See Underhood Apron - Rear (Remove and Install).
97. Install the tonneau slats. See Slat System - Tonneau (Remove and Install).
98. Exit Service Mode. See Service Mode.
99. Raise the LH front window and close the LH front door.
100. Remove the vehicle from the lift. See Raise Vehicle - 2 Post Lift.