23/07/2024 17:31:43

HV Harnesses - Rear Drive Unit - High Voltage Harness - Dual Motor (Remove and Install)

Correction code 4450074021 4450074022 FRT 1.02 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 LaborTimeFeedback@tesla.com. NOTE: See Personal Protection to make sure wearing proper PPE when performing the below procedure.

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. Provide corrections and feedback to ServiceDevelopment@teslamotors.com.

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.

Open LH front door

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Push LH B-pillar door trigger to release
Lower LH front window
Open tonneau cover

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Press forward arrow on LH bed rail
Open tailgate

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Press button to release
Raise and support vehicle

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Set air suspension to "Jack Mode"
Open powered front trunk

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Via exterior switch or UI
Remove rear underhood apron

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9x clips
Power down vehicle via UI

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Verify EPBs are engaged, Select charge port icon to ensure drive state is disengaged then power down vehicle via Controls > Safety > Power Off
Unlock fireman's loop connector and disconnect, Slide eCPA to left on the MV battery connector then lift lever to release

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2x connectors, Unlock fireman's loop connector and disconnect, Release eCPA by pushing down to unlock and slide red locking tab to left, Wait 2 minutes for electrical circuits to discharge before disconnecting modules
Remove RH rear wheel cap

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1x cap, 8x clips, Use both hands to firmly pull wheel cap to release clips, Cap may remove with or without mounting ring attached
Loosen RH rear wheel nuts

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6x nuts, 21mm, 205 Nm
Remove fastener covers from bed floor assembly

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6x covers
Remove bed floor assembly

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10x bolts, 15mm, 56 Nm, 4x anchors, Open anchors as needed, Lift front edge with trim tool then remove panel, Recommend assistance
Release pressurized pack air line to Ancillary

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1x connector, Do not release air line to reservoir, Rapid loss of pressure will result if wrong air line is released.
Remove VOSS fitting from pressurized pack air line to Ancillary

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1x VOSS fitting, Slide threaded section back, Remove the collet, Then slide threaded section off of air line, Discard after removal
Release pressurized pack valve block from air suspension reservoir

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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
Release air suspension valve block

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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
Release air suspension reservoir

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2x nuts, 13mm, 33 Nm, 2x fir tree clips
Place air suspension reservoir in service position then install Ancillary Access Bench

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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
Remove fasteners securing forward section of RDU HV harness

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2x bolts, 10mm, 11 Nm
Raise vehicle partially and lower onto locks

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Set vehicle to comfortable working height, Make sure there's an audible click of the locks on both sides before lowering, otherwise vehicle may tilt to the side
Remove RH rear wheel

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6x nuts, 21mm, 205 Nm
Remove RH rear wheel liner

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19x push clips, 5x push nuts, Discard push nuts after removal
Remove Mid-aero shield

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6x clips, 3x bolts, 15mm, 42 Nm, 5x bolts, 13mm, 28 Nm, 2x bolts, 10mm, 6 Nm
Remove all items from pockets and ensure not wearing metal items
Inspect HV insulating gloves

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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
Put on HV insulating gloves and leather over gloves
Verify no HV - Install amp clamp to RDU HV harness

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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
Remove leather over gloves and HV insulating gloves
Remove rear drive unit HV harness

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4x bolts, T30, 5 Nm, 2x cable ties, 1x clips, Cut cable ties to free harness from bracket, Be extremely cautious when cutting near HV cables, Maneuver out of vehicle
Install rear drive unit HV harness

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4x bolts, T30, 5 Nm, 2x cable ties, 1x clips, Maneuver into position, Install new cable ties, Trim cable ties flush, Be extremely cautious when cutting near HV cables
Install Mid-aero shield

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6x clips, 3x bolts, 15mm, 42 Nm, 5x bolts, 13mm, 28 Nm, 2x bolts, 10mm, 6 Nm, Apply Loctite 222 onto mid aeroshield bolts and install fasteners
Install RH rear wheel liner

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19x push clips, 5x push nuts, Install new push nuts, Use of a socket and dead blow hammer can aid installation
Install RH rear wheel

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6x nuts, 21mm, 205 Nm
Lower vehicle until tires are touching the ground

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Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
Install fasteners securing forward section of RDU HV harness

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2x bolts, 10mm, 11 Nm
Remove Ancillary Access Bench then place air suspension reservoir into position for installation

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Ensure air lines are not twisted, Ensure no harnesses are caught
Secure air suspension reservoir

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2x nuts, 13mm, 33 Nm, 2x fir tree clips
Secure air suspension valve block

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

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1x VOSS fitting, 12mm, 8 Nm, Do not remove VOSS plastic plug until pressurized pack line is installed
Secure pressurized pack air line from Ancillary to valve block

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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
Secure pressurized pack valve block to air suspension reservoir

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

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10x bolts, 15mm, 56 Nm, 4x anchors, Open and close anchors as needed, Recommend assistance
Install fastener covers onto bed floor assembly

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6x covers
Torque RH rear wheel nuts

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6x nuts, 21mm, 205 Nm
Install RH rear wheel cap

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1x cap, 8x clips, Partially secure wheel cap to wheel, While partially installed wheel cover can be rotated to align with tire design, When aligned press inward from center of cap then secure all clips to mounting ring
Slide eCPA to the right and ensure it is seated against the black lever, Connect fireman's loop 20 seconds after eCPA engagement

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2x connectors, Slide and secure red locking tab on top of release lever, Lock fireman's loop connection, If power cycling vehicle ensure at least 60 seconds has passed since powering down
Install rear underhood apron

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9x clips, Adjust windshield seal as required
Close powered front trunk

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Via exterior switch or UI
Close tonneau cover
Close tailgate
Remove vehicle from lift

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Lower rack arms fully and remove them from under vehicle, Remove air suspension from "Jack Mode"
Raise LH front window
Close LH front door