Correction code 1630010181 1630010182 FRT 3.18 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. Power down vehicle via UI
4. Remove the rear underhood apron. See Underhood Apron - Rear (Remove and Install).
5. Disconnect MV power. See Disconnect MV Power.
6. 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

   

   

7. Raise vehicle fully
   Note

   Set to a comfortable working height, Lower to locks, Ensure locks engage on both sides to prevent tilting
8. Remove the rear skid plate. See Skid Plate - Rear (Remove and Install).
9. Disconnect pressurized pack lines
   Note

   12mm, 8Nm

   

10. Remove all items from pockets and ensure not wearing metal items
11. 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.

    

12. Put on HV insulating gloves and leather over gloves

    

13. 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

    

    

    

    

    

    

14. 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

    

    

15. Remove Pyro Fuse Access cover
    Note

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

    

16. Remove primary pyro fuse
    Note

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

    

    

17. Remove secondary pyro fuse
    Note

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

    

    

18. Remove leather over gloves and HV insulating gloves
19. 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
20. Remove bed floor assembly
    Note

    10x bolts, 15mm, 56 Nm, 4x anchors, Open anchors as needed, Lift front edge with trim tool then remove panel, Recommend assistance

    

    

    

21. 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

    

    

    

22. 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

    

    

    

    

    

    

23. 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

    

    

    

24. 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

    

    

    

    

    

    

25. Remove tonneau coverbox cross supports
    Note

    8x screws, T25, 5 Nm

    

    

26. 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

    

27. Release ANC air line from pressurized pack valve block
    Note

    1x VOSS fitting, 12mm, 8 Nm, Do not release air line to reservoir, Rapid loss of pressure will result if wrong air line is released

    

28. Release pressurized pack valve block from air suspension reservoir
    Note

    1x bolt, 10mm, 5 Nm, 1x connector, 1x clip, 1x zip tie, Release lock before connector disengagement, Cut zip tie at reservoir and ancillary air line bundle

    

    

29. 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

    

    

    

30. Release air suspension reservoir
    Note

    2x nuts, 13mm, 33 Nm, 2x fir tree clips

    

    

31. Place air suspension reservoir in service position then install Ancillary Access Bench
    Note

    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

    

    

    

32. 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

    

    

    

    

    

33. 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.

    

34. Put on HV insulating gloves and leather over gloves

    

35. Remove bolt securing busbar HV connector lid
    Note

    1x bolt, EP10, 9 Nm

    

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

    2x bolts, 10mm, 9 Nm

    

37. Release HV connector from DC FC header
    Note

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

    

38. Support HV Busbar assembly
    Note

    Suspend assembly to maintain clearance

    

39. Remove fast charger header doubler
    Note

    2x bolts, E10 5 Lobe Torx, 10 Nm

    

    

40. Release low voltage header
    Note

    2x bolts, 10mm, 6 Nm

    

41. 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

    

    

    

42. Remove ancillary cover
    Note

    Use suction cup and maneuver around busbar and tonneau cage

    

    

    

43. Remove DC 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

    

    

    

44. Remove DCA splash shield
    Note

    2x clips

    

    

    

45. Disconnect FC connector
    Note

    2x clip, squeeze the clips on the side and pull up

    

    

46. Remove AC junction box to contactor harness
    Note

    2x connectors, 2x clips, 2x bolts, 13mm, 5 Nm + 60 degrees, inspect harness part number, if not rev J or newer harness must be replaced

    

    

    

47. Install AC junction box to contactor harness
    Note

    2x connectors, 2x clips, 2x bolts, 13mm, 5 Nm + 60 degrees

    

    

48. Perform Hioki impedance measurement at FC contactor positive joint to positive DC oulet busbar
    Note

    1x HV joint, 102μΩ or less, Perform zero adjust to Hioki meter prior to testing

    

49. Perform Hioki impedance measurement at FC contactor negative joint to negative DC outlet busbar
    Note

    1x HV joint, 102μΩ or less, Perform zero adjust to Hioki meter prior to testing

    

50. Connect FC connector
    Note

    2x Clip, perform push pull test to verify the connector is fully seated

    

    

51. Install DCA splash shield
    Note

    2x clip

    

    

52. Install DC header
    Note

    1x connector, 1x tree clip, Slide header on to DC bus links, connector is hidden under the seal, Inspect seal, Replace header if damaged

    

    

    

    

53. Install ancillary cover
    Note

    Use suction cup and maneuver around busbar and tonneau cage

    

    

    

    

54. 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

    

    

    

55. Secure low voltage header
    Note

    2x bolts, 10mm, 6 Nm

    

56. Secure fast charger header doubler
    Note

    2x bolts, E10 5 Lobe Torx, 10Nm

    

    

57. 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

    

58. 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

    

59. 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

    

60. Position busbar connector and lower onto HV header
    Note

    Release bungee cord

    

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

    2x bolts, 10mm, 9 Nm

    

62. 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

    

    

63. Remove leather over gloves and HV insulating gloves
64. Install bolt securing busbar HV connector lid
    Note

    1x bolt, EP10, 9 Nm

    

65. Connect Ancillary bay MV connector
    Note

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

    

    

    

    

    

66. Secure tonneau coverbox cross supports
    Note

    8x screws, T25, 5 Nm, Supports install in the same direction of the fasteners

    

    

67. 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

    

    

    

    

    

    

68. 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

    

    

    

69. 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

    

    

    

    

    

    

70. 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

    

    

    

71. Remove Ancillary Access Bench then place air suspension reservoir into position for installation
    Note

    Ensure air lines are not twisted, Ensure no harnesses are caught

    

    

    

72. Secure air suspension reservoir
    Note

    2x nuts, 13mm, 33 Nm, 2x fir tree clips

    

    

73. Secure air suspension valve block
    Note

    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

    

    

    

74. Secure ANC air line onto pressurized pack valve block
    Note

    1x line, Remove plastic cap from VOSS fittings, Press air lines onto fitting until mark aligns with top of fitting, Verify line is properly secured by performing push and pull test

    

    

75. Secure pressurized pack valve block onto air suspension reservoir
    Note

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

    

    

76. Install bed floor assembly
    Note

    10x bolts, 15mm, 56 Nm, 4x anchors, Open and close anchors as needed, Recommend assistance

    

    

    

77. Raise vehicle fully
78. Put on HV insulating gloves and leather over gloves

    

79. 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

    

    

    

80. Install secondary pyro fuse
    Note

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

    

    

81. Install primary pyro fuse
    Note

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

    

    

82. 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

    

    

    

83. Remove leather over gloves and HV insulating gloves
84. Install Pyro Fuse Access cover
    Note

    4x bolts, E-Torx 5 lobe, 10 Nm, Ensure seal is fully seated and undamaged

    

    

85. Install pressurized pack lines
    Note

    2x VOSS fittings, 12mm, 8 Nm, Remove plastic caps 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

    

    

    

86. Install the rear skid plate. See Skid Plate - Rear (Remove and Install).
87. Lower vehicle fully
    Note

    Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
88. Reconnect MV power. See Disconnect MV Power.
89. Install the rear underhood apron. See Underhood Apron - Rear (Remove and Install).
90. Close the powered frunk.
91. Install the tonneau slats. See Slat System - Tonneau (Remove and Install)
92. Remove the vehicle from the lift. See Raise Vehicle - 2 Post Lift.