Correction code NEW 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.

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. Run ODIN routine PROC_ICE_X_ENTER-SERVICE-MODEvia Toolbox: (link)
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. Open powered front trunk
   Note

   Via exterior switch or UI

   

   

7. Remove fastener covers from bed floor assembly
   Note

   14x covers

   

   

   

   

   

8. 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

   

   

   

   

9. 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

   

10. Remove rear underhood apron
    Note

    9x clips

    

    

11. 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

    

    

    

12. 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

    

    

13. Raise vehicle fully
    Note

    Set to a comfortable working height, Lower to locks, Ensure locks engage on both sides to prevent tilting

    

    

14. Remove rear skid plate
    Note

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

    

    

    

    

    

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

    

16. Inspect HV insulating gloves
    Note

    Check gloves for damage prior to use, Refer to service document TN-15-92-003

    

17. Put on HV insulating gloves and leather over gloves

    

18. 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

    

    

    

    

    

    

19. Remove pyro fuse access cover
    Note

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

    

20. Remove primary pyro fuse
    Note

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

    

    

21. Remove secondary pyro fuse
    Note

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

    

    

22. 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

    

    

23. Release 2x4 header assembly
    Note

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

    

    

24. Release drive unit connectors from ancillary headers
    Note

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

    

    

    

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

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

    

    

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

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

    

    

27. 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

    

    

28. 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

    

    

    

    

    

29. Remove bolt securing busbar HV connector lid
    Note

    1x bolt, EP10, 9 Nm

    

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

    2x bolts, 10mm, 9 Nm

    

31. Release HV connector from DC FC header
    Note

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

    

32. Support HV Busbar assembly
    Note

    Suspend assembly to maintain clearance

    

33. Remove fast charger header doubler
    Note

    2x bolts, E10 5 Lobe Torx, 10 Nm

    

    

34. Release low voltage header
    Note

    2x bolts, EP10, 6 Nm

    

35. 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

    

    

    

36. Remove ancillary cover
    Note

    Use suction cup and maneuver around busbar and tonneau cage

    

    

    

37. Remove DC header
    Note

    Slide header off DC bus links, Inspect seal, Replace header if damaged

    

    

    

38. 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

    

    

39. Release PCS MV harness
    Note

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

    

40. Release MV header
    Note

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

    

    

    

41. 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

    

    

    

    

    

42. Release BMB passthrough connectors
    Note

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

    

    

    

43. 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

    

    

    

44. Remove MV ancillary harness

    

    

45. Release HVC harness from PCS
    Note

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

    

46. Release device cluster busbar fasteners
    Note

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

    

    

    

    

47. Remove device cluster assembly fasteners
    Note

    4x bolts, E10 5 Lobe Torx, 6Nm

    

    

    

    

48. 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

    

    

49. 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

    

    

    

50. Secure device cluster assembly fasteners
    Note

    4x bolts, E10 5 Lobe Torx, 6Nm

    

    

    

    

51. Secure device cluster busbar fasteners
    Note

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

    

    

    

    

52. 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

    

    

    

    

    

    

    

    

    

53. Secure HVC harness to PCS
    Note

    1x connectors, Secure connector lock

    

54. Poistion MV ancillary harness for install

    

    

55. Secure ACJB LV and HV connectors
    Note

    2x clips, 2x connectors, Secure connector locks

    

    

    

56. 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

    

    

    

57. 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

    

    

    

    

    

58. Secure MV header
    Note

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

    

    

59. Secure PCS MV harness
    Note

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

    

60. 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

    

    

    

    

61. Install DC header
    Note

    Slide header on to DC bus links, Inspect seal, Replace header if damaged

    

    

    

62. Install ancillary cover
    Note

    Use suction cup and maneuver around busbar and tonneau cage

    

    

    

    

63. 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

    

    

    

64. Secure low voltage header
    Note

    2x bolts, EP10, 6 Nm

    

65. Secure fast charger header doubler
    Note

    2x bolts, E10 5 Lobe Torx, 10Nm

    

    

66. 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

    

67. 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

    

68. 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

    

69. Position busbar connector and lower onto HV header
    Note

    Release bungee cord

    

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

    2x bolts, 10mm, 9 Nm

    

71. 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

    

    

72. Install bolt securing busbar HV connector lid
    Note

    1x bolt, EP10, 9 Nm

    

73. Remove leather over gloves and HV insulating gloves
74. Connect Ancillary bay MV connector
    Note

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

    

    

    

    

    

75. Raise vehicle fully

    

76. Inspect HV insulating gloves
    Note

    Check gloves for damage prior to use, Refer to service document TN-15-92-003

    

77. Put on HV insulating gloves and leather over gloves

    

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

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

    

    

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

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

    

    

80. Secure 2x4 header assembly
    Note

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

    

    

    

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

    2x connectors, Fully engage red lock tab

    

    

82. Secure drive unit connectors to ancillary headers
    Note

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

    

    

    

83. Install secondary pyro fuse
    Note

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

    

    

84. Install primary pyro fuse
    Note

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

    

    

85. 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

    

    

86. 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

    

    

87. Remove leather over gloves and HV insulating gloves
88. Install Mid-aero shield
    Note

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

    

    

    

    

    

89. 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

    

    

90. Connect FRL connector then connect 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

    

    

    

91. Install rear underhood apron
    Note

    9x clips, Adjust windshield seal as required

    

    

92. Close powered front trunk
    Note

    Via exterior switch or UI

    

93. Install bed floor assembly
    Note

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

    

    

    

    

    

94. Install fastener covers onto bed floor assembly
    Note

    14x covers

    

    

    

    

95. Run ODIN routine PROC_ICE_X_EXIT-SERVICE-MODEvia Toolbox: (link)
96. Raise LH front window

    

97. Close LH front door

    

98. Remove vehicle from lift
    Note

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