Correction code 16102200 1.44 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

   If vehicle has air suspension set to Jack Mode", Align lift adapter pins with lift point holes on body, Ensure vehicle is not charging, Remove charging cable if it's plugged in

   

   

2. Open LH front door
   Note

   Push LH B-pillar door trigger to release
3. Lower LH front window
4. Open tonneau cover
   Note

   Press forward arrow on LH bed rail
5. Open tailgate
   Note

   Press button to release, Use manual release as necessary
6. Remove fastener covers from bed floor assembly
   Note

   14x covers

   

   

   

   

   

7. Remove bed floor assembly
   Note

   12x short bolts, 15mm, 56 Nm, 2x long bolts, 15mm, 46Nm, Lift front edge with trim tool then remove panel, Recommend assistance

   

   

   

   

8. 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*part number for bolts needed

   

   

   

9. 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

   

   

   

   

   

   

10. 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

    

    

    

11. 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

    

    

    

    

    

    

12. Close tonneau cover partially for access to ancillary area
    Note

    Press forward arrow on LH bed rail

    

13. Open powered front trunk
    Note

    Via exterior switch or UI

    

    

14. 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

    

15. Remove rear underhood apron
    Note

    9x clips

    

    

16. 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

    

    

    

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. 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

    

    

19. Remove mid-aero shield
    Note

    6x clips, 3x bolts, 15mm, 42 Nm, 5x bolts, 13mm, 28 Nm, 2x bolts, 10mm, 6 Nm(*15mm & 10mm bolts not shown in catalog, feedback sent)

    

    

    

    

    

20. Remove all items from pockets and ensure not wearing metal items
    Note

    This includes phones, badges, metal belt buckles airpods and headphones

    

21. 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.

    

22. 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

    

23. 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

    

    

    

    

    

    

24. 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

    

    

25. Inspect thermal vent breather plugs
    Note

    4x plugs, If plug has laser etchings in line then replace, If plug is loose then press to get audible click

    

    

    

26. Inspect pyro access cover breather plug
    Note

    1x plug, If plug has laser etchings in line then replace, If plug is loose then press to get audible click

    

    

    

27. Loosen bolts securing 2x4 header assembly to enclosure
    Note

    4x bolts, 5-lobe E10, 6 Nm, Use hand tools only, Adjust assembly as needed, Do not remove connectors unless soft set is found

    

28. Torque bolts securing 2x4 header assembly to enclosure
    Note

    4x bolts, 5-lobe E10, 6 Nm, Use hand tools only, Adjust assembly as needed, Do not remove connectors unless soft set is found

    

29. Remove breather plug from thermal vent
    Note

    1x plug, 3x tabs per plug, Discard after removal

    

    

    

30. Apply butyl onto remaining thermal vents
    Note

    3x butyl patches, 3x thermal vents

    

    

31. Install enclosure leak test adapter onto open thermal vent
    Note

    1x thermal vent

    

    

32. Connect enclosure leak tester onto adapter
    Note

    1x adapter

    

33. Close both valves on regulator

    

34. Connect regulator to air supply

    

35. Turn right side regulator valve to open position
    Note

    Turn valve knob to horizontal position

    

36. Set regulator to 0.3 psi

    

37. Open left side regulator valve to inject air into platter
    Note

    Close right side regulator valve when pressure reaches 0.3 psi and stabilizes, Allow platter to fill for 120 seconds

    

    

38. Wait 30 seconds for pressure to settle
39. Record value of starting pressure
40. Wait 30 seconds to test pressure
41. Record value of end pressure
    Note

    Subtract ending pressure from starting pressure, If difference is greater than 0.006 psi then inspect tools and retest, If difference is still greater than 0.006 psi then escalate to Service Engineering, If difference is 0.006 psi or less then proceed with current procedure
42. Remove enclosure leak test adapter from open thermal vent
    Note

    1x thermal vent

    

    

43. Remove butyl from remaining thermal vents
    Note

    3x butyl patches, 3x thermal vents

    

    

44. Install breather plug onto thermal vent
    Note

    1x plug, 3x tabs per plug, Install new plug, Press plug evenly, Make sure tabs are fully engaged and plug is flush with vent

    

    

45. Remove breather plug from pyro access cover
    Note

    1x plug, 3x tabs per plug, Discard after removal

    

    

    

46. Install enclosure leak test adapter onto pyro access cover breather hole
    Note

    1x thermal vent

    

47. Close both valves on regulator

    

48. Turn right side regulator valve to open position
    Note

    Turn valve knob to horizontal position

    

49. Set regulator to 0.3 psi

    

50. Open left side regulator valve to inject air into ancillary bay
    Note

    Close right side regulator valve when pressure reaches 0.3 psi and stabilizes, Allow bay to fill for 120 seconds

    

    

51. Wait 30 seconds for pressure to settle
52. Record value of starting pressure
53. Wait 30 seconds to test pressure
54. Record value of end pressure
    Note

    Subtract ending pressure from starting pressure, If difference is greater than 0.05 psi then inspect tools and retest, If difference is still greater than 0.05 psi then escalate to Service Engineering, If difference is 0.05 psi or less then proceed with current procedure
55. Close both valves on regulator

    

56. Turn right side regulator valve to open position
    Note

    Turn valve knob to horizontal position

    

57. Set regulator to 0.8 psi

    

58. Open left side regulator valve to inject air into ancillary bay
    Note

    Close right side regulator valve when pressure reaches 0.8 psi and stabilizes, Allow bay to fill for 120 seconds

    

    

59. Inspect 2x4 header assembly for air leak
    Note

    2x headers, Spray with soapy water as needed, Do not disconnect connectors, If leak found then proceed to replacement procedure

    

60. Inspect pyro access cover for air leak
    Note

    Spray with soapy water as needed, If leak found then proceed to replacement procedure

    

61. Inspect PCS coolant passthrough for air leak
    Note

    2x hoses, Spray with soapy water as needed, Do not disconnect hoses, If leak found then proceed to replacement procedure

    

62. Inspect DU HV headers for air leak
    Note

    3x headers, Spray with soapy water as needed, Do not disconnect connectors, If leak found then proceed to replacement procedure

    

63. Inspect ancillary bay flood ports for air leak
    Note

    3x ports, Spray with soapy water as needed, If leak found then proceed to replacement procedure

    

64. 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
65. Remove bolt securing busbar HV connector lid
    Note

    1x bolt, EP10, 9 Nm

    

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

    2x bolts, 10mm, 9 Nm

    

67. Release HV connector from DC FC header
    Note

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

    

68. Install CP busbar dummy plug onto DC FC header
    Note

    1x bolt, 10mm, 9 Nm, Shift plug up and down a few times to work grease onto seal grooves

    

    

    

69. Raise vehicle fully
    Note

    Set to a comfortable working height, Lower to locks, Ensure locks engage on both sides to prevent tilting
70. Close both valves on regulator

    

71. Turn right side regulator valve to open position
    Note

    Turn valve knob to horizontal position

    

72. Set regulator to 0.3 psi

    

73. Open left side regulator valve to inject air into ancillary bay
    Note

    Close right side regulator valve when pressure reaches 0.3 psi and stabilizes, Allow bay to fill for 120 seconds

    

    

74. Wait 30 seconds for pressure to settle
75. Record value of starting pressure
76. Wait 30 seconds to test pressure
77. Record value of end pressure
    Note

    Subtract ending pressure from starting pressure, If difference is greater than 0.05 psi then inspect tools and retest, If difference is still greater than 0.05 psi then escalate to Service Engineering, If difference is 0.05 psi or less then proceed to repair procedure
78. Disconnect air supply from regulator

    

79. Disconnect enclosure leak tester from adapter
    Note

    1x adapter

    

80. Remove enclosure leak test adapter from pyro access cover breather hole
    Note

    1x thermal vent

    

81. Install rear skid plate
    Note

    6x clips, 3x bolts, 15mm, 42 Nm, 5x bolts, 13mm, 28 Nm, 2x bolts, 10mm, 6 Nm, Apply Loctite 222 to mid aero shield bolts and install fasteners

    

    

    

    

    

82. Lower vehicle fully
    Note

    Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
83. Remove CP busbar dummy plug from DC FC header
    Note

    1x bolt, 10mm, 9 Nm

    

    

84. Position busbar connector and lower onto HV header
    Note

    Release bungee cord

    

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

    2x bolts, 10mm, 9 Nm

    

86. 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

    

    

87. Install bolt securing busbar HV connector lid
    Note

    1x bolt, EP10, 9 Nm

    

88. Remove leather over gloves and HV insulating gloves
89. 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

    

    

    

    

    

    

90. 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

    

    

    

91. 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

    

    

    

    

    

    

92. 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

    

    

    

93. Install bed floor assembly
    Note

    12x short bolts, 15mm, 56 Nm, 2x long bolts, 15mm, 46Nm, Recommend assistance

    

    

    

    

    

94. Install fastener covers onto bed floor assembly
    Note

    14x covers

    

    

    

    

95. 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

    

    

    

96. Install rear underhood apron
    Note

    9x clips, Adjust windshield seal as required

    

    

97. Close powered front trunk
    Note

    Via frunk switch or UI
98. Close tonneau cover
99. Close tailgate
100. Remove vehicle from lift
     Note

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

     

101. Raise LH front window
102. Close LH front door