2026-06-25

Device Cluster Assembly (Remove and Replace)

Correction code 1630010112 FRT 3.96 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.

2026-06-25: Updated procedure to latest validation.
2026-04-02: Updated instructions for connecting MV battery maintainer.
2025-10-21: Deleted steps to enter Service Mode and unlock the Gateway.
2024-12-05: Added note to replace the header plug with PN 1507801-20-E or later if the new device cluster has PN 1816026-XX-J or later.
2024-11-22: Added warning to NOT skip steps to remove the tonneau slats.
2024-10-11: Added replacement device cluster image with pre-installed pyro disconnects shown for clarity purposes.
2024-07-26: Added steps to back up and restore DCA; removed old placeholder steps.
2024-07-23: Added steps to check and adjust orientation of the shunts on replacement device cluster assembly before installing.
2024-04-09: Added check for pre-installed pyro disconnects and removal steps.
2024-03-27: Cleaned up topic.

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

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.

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.

Note

If the new device cluster has PN 1816026-XX-J or later, the header plug must be replaced with PN 1507801-20-E or later. Refer to HV Connector Header, Plug (Remove and Install) to replace the header plug.

Remove

Inspect the replacement device cluster for the presence of pre-installed pyro disconnects.

Warning
Do not install a device cluster with pre-installed pyro disconnects.
- If the replacement device cluster has no pre-installed pyro disconnects, go to step #GUID-46B38203-5311-4654-8951-E115F267FD29__GUID-022E4A5A-5D3A-4196-89FC-96D8FFDD53F7.
- If the replacement device cluster has any pre-installed pyro disconnects, continue to the next step.
Remove the bolts (x2) that attach the primary pyro disconnect to the device cluster, and then remove the pyro disconnect from the device cluster.
TIp
Use of the following tool(s) is recommended:

13 mm socket
Remove the bolts (x2) that attach the secondary pyro disconnect to the device cluster, and then remove the pyro disconnect from the device cluster.
TIp
Use of the following tool(s) is recommended:

13 mm socket
Put the removed pyro disconnects into the service center's parts inventory.
Inspect the orientation of the shunts on the replacement device cluster to confirm both shunts are in the correct position. Refer to the images below for the correct and incorrect orientations.

CAUTION
Do not install a new device cluster assembly with either shunt in the incorrect orientation. Installing an assembly with either shunt in the incorrect orientation may result in the vehicle exhibiting unexpected displayed UI range and subpack imbalance issues.

Figure 1. Correct orientation

Figure 2. Incorrect orientation

Figure 3. Incorrect orientation

Figure 4. Incorrect orientation
If a shunt is in the incorrect orientation, gently pull the harness end of the shunt upward and away from the device cluster assembly to release it, rotate the shunt to the correct orientation, and then reinstall the shunt into the assembly.
Raise and support the vehicle. See Raise Vehicle - 2 Post Lift.
Open the LH front door and lower the LH front window.
Open the powered frunk.
Open the tailgate.
Open the tonneau cover.
Place the vehicle into Service Mode. See Service Mode.
Unlock the vehicle Gateway. See Gateway (Unlock).
Remove the tonneau slats. See Slat System - Tonneau (Remove and Install).
Run ODIN routine PROC_ICE_X_ENTER-SERVICE-MODE-PLUSvia Toolbox:(link)
On the vehicle touchscreen, navigate to Service UI > High Voltage Tab > Procedures > Device Cluster Assembly (DCA) Replacement > Backup Old DCA, and then tap Run to back up the device cluster assembly.

Note
Allow the routine to complete before continuing.

Note
Make sure the routine completes successfully.
Disconnect MV power. See Mid-Voltage Power (Disconnect and Connect) (Modify).
Perform vehicle electrical disablement procedure. See Vehicle HV Disablement Procedure (Test/Adjust).
Remove pyro fuse access cover with airlines attached

Note
4x bolts, E-Torx 5 lobe, 10 Nm, Remove cover bolts, Release two airline mounting clips from HV Battery, Do not loosen or remove airline fittings from cover
Reposition pyro cover for access to pyro fuses

Note
1x cover, 2x clips, Move cover to the side and secure to the HV Battery with clamp(*This step is to prevent the need to disconnect airlines from cover)
Remove primary and secondary pyro fuses

Note
4x bolts, 13mm, 5 Nm + 60 Degrees, Support each pyro fuse while removing bolts
Partially install pyro fuse access cover to protect ancillary from contaminates, debris, or coolant ingress during service

Note
4x bolts, E-Torx 5 lobe, 10 Nm, Tighten until snug, Torque not required at this time, only temporary installation
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
Release 2x4 header assembly

Note
4x bolts, 5-lobe 10mm, 6 Nm
Release drive unit connectors from ancillary headers

Note
3x connectors, Release blue lock tab, Rotate black latch
Remove bolts securing HC-Stak HV Headers for LHRDU, FDU, RHRDU from ancillary flange

Note
6x bolts, 5-lobe 10mm, 10 Nm
Remove LHRDU, FDU, RHRDU headers from ancillary flange

Note
3x headers, No tools required, inspect header seals, Replace header if damaged
Remove leather over gloves and HV insulating gloves
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
Remove the bed floor. See Bed Floor Assembly (Remove and Install).
Install Ancillary Access Bench into bed floor opening.

Note
1x bench, place above rear casting ensuring no air lines or harnesses are being pinched(*No image available or access bench in LONG RANGE/STANDARD truck bed)
Disconnect harness pigtail from scuba valve and air reservoir

Note
1x connector, 1x clip, release red locking clip on connector to disconnect from valve, Release harness clip from air reservoir
Disconnect ANC air line from scuba valve block

Note
1x VOSS fitting, 12mm, 3.5 Nm, 1x cable tie, Disconnect lower airline and fitting with brown color tape indicator and "ANC" label, Do not release air line to reservoir, Rapid loss of pressure will result if wrong air line is released, Cut cable tie to release airline from bundle
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
Remove air suspension reservoir fasteners

Note
2x nuts, 13mm, 33 Nm, 2x fir tree clips, Wrench needed on right side nut due to low clearance to bed trim, Disconnect harness fir clips from each end of reservoir assembly
Place air suspension reservoir in service position

Note
Raise and swing air suspension reservoir to the side of the bed, Ancillary access bench may need to be temporarily removed to position air reservoir, Place Ancillary Access Bench back into bed ensuring no air lines or harnesses are being pinched
Remove the tonneau NVH barrier. See Tonneau NVH Barrier Assembly (Remove and Install).
Remove the screws (x8) that attach the tonneau coverbox cross supports.
5 Nm (3.7 lbs-ft)
Note
2x support braces, Remove two square support braces that are closest to rear of vehicle, Remove bolts at each end of support braces, Slide braces off of mounting points on flat cassette assemblies, Braces slide off in same direction of fasteners, maneuver each brace out of bed opening
TIp
Use of the following tool(s) is recommended:

Torx T25 socket
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
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
Remove mid voltage header bolts

Note
2x bolts, EP10, 6 Nm
Remove bolt securing busbar HV connector lid

Note
1x bolt, EP10, 9 Nm
Remove the bolts (x2) that attach the HV connector to the DC FC header.
9 Nm (6.6 lbs-ft)
TIp
Use of the following tool(s) is recommended:

10 mm socket
Release HV connector from DC FC header

Note
1x connector, Use inflatable airbag if needed to suspend busbar assembly above ancillary assembly
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
Remove fast charger header doubler

Note
2x bolts, E10 5 Lobe Torx, 10 Nm
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
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.
Put on HV insulating gloves and leather over gloves
Remove ancillary cover

Note
Install vacuum cup to ancillary cover surface, Lift and maneuver cover around busbar and tonneau cage to remove
Remove fast charge HV connector 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
Release MV header from device cluster assembly

Note
4x datums, 1x edge clip, 1x fir tree clip
Release HVC connectors from device cluster assembly

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.*Replacement Device clusters with newer REV do not require sealant at connections.*If reinstalling the same Device cluster (not replacing) re-apply grey sealant during the installation process if sealant was present during removal.
Release BMB passthrough connectors

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

Note
Lay loose section of ancillary harness on top of PCS out of work area
Release device cluster HV harness from PCS

Note
1x connectors, Release connector lock, Depress lever and pull at connector, Do not pull at harness
Remove the device cluster busbar bolts (x4).
TIp
Use of the following tool(s) is recommended:

Torx 55
Note
Torque: 5 Nm + 60 degrees

Note
Captured bolts with insulated covers.
Remove the device cluster assembly bolts (x4).
6 Nm (4.4 lbs-ft)
TIp
Use of the following tool(s) is recommended:

External Torx E10 5-Lobe
Remove the device cluster from the ancillary tray.

Warning
Make sure to wear Personal Protection Equipment (PPE) such as HV gloves and safety glasses when working on HV component.

Note
Put the device cluster on a stand to protect the headers at the bottom of the assembly.

Note
Remove the lifting/install tool.

Install

Note

Install the device cluster assembly, but perform the following steps after the installation of the "mid aero shield" but before "connect MV power." See Device Cluster Assembly (Remove and Install).
1. Connect the MV battery maintainer, but leave the MV battery connected: Attach the positive terminal to jump post, and then attach the negative terminal to the bolt located between the brake fluid reservoir and the front trunk.
2. Connect the MV battery maintainer to power supply.
  
  Warning
  DO NOT allow the positive cable to make contact with other metal components. Prevent shorting the cables.
  
  CAUTION
  Do not have the MV battery maintainer and the MV battery simultaneously connected for any extended period of time.
3. Reestablish vehicle connection to Toolbox 3.
4. On the vehicle touchscreen, navigate to Service UI > High Voltage Tab > Procedures > Device Cluster Assembly Replacement > Restore New DCA, and then tap Run to restore the device cluster assembly.
  
  Note
  Laptop must be connected via Toolbox 3 for duration of routine. Follow all on screen instructions and requirements. Do not disconnect Toolbox 3 until routine completes successfully.
5. Power down the vehicle through the vehicle touchscreen.
  
  Note
  Verify EPBs are engaged. Touch the charge port icon to ensure the drive state is disengaged, and then power down vehicle via Controls > Safety > Power Off.
6. Remove the MV battery maintainer from the vehicle.
  
  Note
  Unplug the MV battery maintainer first from the power outlet, and then remove the positive and negative leads from the jump posts.