2026-08-09

HV Connector - Busbar - Charge Port (Long Range) (Remove and Install)

Correction code 44500300301 1.08 NOTE: Unless otherwise explicitly stated in the procedure, the correction code and its associated 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. 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.

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.
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.
Warning
Only technicians who have been trained in High Voltage Awareness and have completed all required certification courses (if applicable) are permitted to perform this procedure. Proper personal protective equipment (PPE) and insulating HV gloves with a minimum rating of class 0 (1000V) must be worn at all times a high voltage cable, busbar, or fitting is handled. Refer to Tech Note TN-15-92-003, High Voltage Awareness Care Points for additional glove and safety information.
  • 2025-06-21: Released new procedure.
  1. Open the LH front door and lower the LH front window.
  2. Raise and support the vehicle. See Raise Vehicle - 2 Post Lift.
  3. Open the tailgate.
  4. Remove the bed floor assembly. See Bed Floor Assembly (Long Range) (Remove and Install).
  5. Disconnect MV power. See Mid-Voltage Power (Disconnect and Connect) (Modify).
  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. Remove all items from pockets and ensure not wearing metal items
  10. Inspect HV insulating gloves
    Note
    Check gloves for damage prior to use, Refer to service document TN-15-92-003
  11. Put on HV insulating gloves and leather over gloves
  12. 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
  13. 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
  14. 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
  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 to suspend busbar assembly above ancillary assembly
  18. Raise CP busbar connector
    Note
    2x inflatable bags, Install bags, Do not open tonneau to prevent damage
  19. Remove screws securing HV connector to CP busbars
    Note
    2x screws, T20, 1.5 Nm, Position mirror as needed
  20. Remove HV connector from CP busbars
    Note
    Gently pry between orange clips and primary heat sink, Pull evenly
  21. Position HV connector onto CP busbars
    Note
    Push evenly, Make sure orange clips are flush with primary heat sink
  22. Install screws securing HV connector to CP busbars
    Note
    2x screws, T20, 1.5 Nm, Position mirror as needed
  23. 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
  24. 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
  25. 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
  26. Lower CP busbar connector
    Note
    2x inflatable bags, Remove bags, Do not open tonneau to prevent damage
  27. Position busbar connector and lower onto HV header
    Note
    Release bungee cord
  28. Install bolts securing charge port busbar kit to HV Header
    Note
    2x bolts, 10mm, 9 Nm
  29. 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
  30. Install bolt securing busbar HV connector lid
    Note
    1x bolt, EP10, 9 Nm
  31. Reconnect MV power. See Mid-Voltage Power (Disconnect and Connect) (Modify).
  32. Install the bed floor assembly. See Bed Floor Assembly (Long Range) (Remove and Install).
  33. Install the rear underhood apron. See Underhood Apron - Rear (Remove and Install).
  34. Close the tonneau cover.
  35. Close the tailgate.
  36. Install the rear skid plate. See Skid Plate - Rear (Remove and Install).
  37. Remove the vehicle from the lift. See Raise Vehicle - 2 Post Lift.
  38. Raise the LH front window and close the LH front door.