Correction code NEW 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 the vehicle. See Raise Vehicle - 2 Post Lift.
2. Remove the tonneau slats. See Slat System - Tonneau (Remove and Install).
3. Disconnect MV power. See Mid-Voltage Power (Disconnect and Connect) (Modify).
4. Perform vehicle HV disablement procedure. See Vehicle HV Disablement Procedure (Test/Adjust).
5. 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

   

   

6. Remove pyro fuse access cover
   Note

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

   

7. Remove primary pyro fuse
   Note

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

   

   

8. Remove secondary pyro fuse
   Note

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

   

   

9. Install pyro fuse access cover with airlines attached
   Note

   4x bolts, E-Torx 5 lobe, 10 Nm, Ensure seal is fully seated and undamaged, Secure 2 airline mounting clips to HV Battery, If HV pack is being shipped then pyro fuses must be removed

   

   

   

10. Remove leather over gloves and HV insulating gloves
11. 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
12. Remove the bed floor assembly. See Bed Floor Assembly (Long Range) (Remove and Install).
13. 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

    

    

    

    

    

14. Put on HV insulating gloves and leather over gloves

    

15. Remove bolt securing busbar HV connector lid
    Note

    1x bolt, EP10, 9 Nm

    

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

    2x bolts, 10mm, 9 Nm

    

17. Release HV connector from DC FC header
    Note

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

    

18. 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

    

    

19. Remove fast charger header doubler
    Note

    2x bolts, E10 5 Lobe Torx, 10 Nm

    

    

20. Remove mid voltage header bolts
    Note

    2x bolts, EP10, 6 Nm

    

21. Release fasteners securing ancillary bay 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

    

    

    

22. Remove ancillary bay cover
    Note

    Install vacuum cup to ancillary bay cover surface, Lift and maneuver cover around busbar and tonneau cage to remove

    

    

    

23. 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

    

    

    

    

24. 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

    

    

    

    

    

25. Install ancillary cover
    Note

    Use suction cup and maneuver around busbar and tonneau cage

    

    

    

    

26. Secure ancillary cover fasteners 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

    

    

    

27. Install mid voltage header bolts
    Note

    2x bolts, EP10, 6 Nm

    

28. Install fast charger header doubler
    Note

    2x bolts, E10 5 Lobe Torx, 10Nm

    

    

29. 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

    

30. 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

    

31. 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

    

32. Position busbar connector and lower onto HV header
    Note

    Release bungee cord

    

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

    2x bolts, 10mm, 9 Nm

    

34. 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

    

    

35. Install bolt securing busbar HV connector lid
    Note

    1x bolt, EP10, 9 Nm

    

36. Connect ancillary bay MV connector
    Note

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

    

    

    

    

    

37. 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
38. Remove pyro fuse access cover
    Note

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

    

39. Clean pyro fuse mating surfaces
    Note

    Using an insulated tool wipe all four busbar mating surfaces within pyro fuse bay, Wipe top and bottom mating surfaces of each pyro fuse, Ensure no debris is present on any mating surface, Process shown with device cluster removed for clarity and safety, HV gloves and associated PPE must be worn at all times when cleaning mating surfaces, Allow 1 minute for IPA to dry

    

    

    

40. Install secondary pyro fuse
    Note

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

    

    

41. Install primary pyro fuse
    Note

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

    

    

42. 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

    

    

43. Install pyro fuse access cover with airlines attached
    Note

    4x bolts, E-Torx 5 lobe, 10 Nm, Ensure seal is fully seated and undamaged, Secure 2 airline mounting clips to HV Battery, If HV pack is being shipped then pyro fuses must be removed

    

    

    

44. Remove leather over gloves and HV insulating gloves
45. Install the rear skid plate. See Skid Plate - Rear (Remove and Install).
46. Lower vehicle fully
    Note

    Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
47. Reconnect MV power. See Mid-Voltage Power (Disconnect and Connect) (Modify).
48. Install the rear underhood apron. See Underhood Apron - Rear (Remove and Install).
49. Install the bed floor assembly. See Bed Floor Assembly (Long Range) (Remove and Install).
50. Install the tonneau slats. See Slat System - Tonneau (Remove and Install).
51. Close the tailgate.
52. Remove the vehicle from the lift. See Raise Vehicle - 2 Post Lift.