Last Mile Busbar Assembly (Long Range) (Remove and Install)
Code de correction
16300106501
16300106502
3.06
REMARQUE : À moins d’indications explicites contraires dans la procédure, le code de correction et le temps forfaitaire indiqués ci-dessus représentent tout le travail à être fait pour cette procédure, notamment les procédures connexes. N’appliquez pas plusieurs codes de correction à la fois, à moins qu’il vous soit explicitement indiqué de le faire.
REMARQUE : Consultez Temps forfaitaires pour en apprendre plus à propos des temps forfaitaires et de leur création.
NOTE : Consultez Protection individuelle pour vous assurer de porter l’équipement de protection individuelle adéquat lorsque vous effectuez la procédure ci-dessous.
REMARQUE : Voir Précautions ergonomiques pour consulter les pratiques de travail sécuritaires et saines.
- 2026-02-26: Released new procedure.
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Raise and support vehicle
RemarqueSet air suspension to "Jack Mode"
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Open LH front door
RemarquePush LH B-pillar door trigger to release
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Lower LH front window
- Mettez le véhicule en mode Entretien. Voir Mode Entretien,
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Unlock vehicle gateway
RemarqueAfter 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
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Access thermal system routines using the UI
RemarqueSelect quick controls > Service mode > Thermal > Actions
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Select "Coolant Fill/Drain" through Service UI
RemarqueSelect 'Coolant System' to enter coolant circuit screen, Select 'Coolant Fill/Drain' and 'PROC_VCFRONT_X_START-THERMAL-FILL-DRAIN-COOLANT' window will appear, Select 'Run', Verify indicator displays green for Coolant readiness, Thermal Fill Drain routine has a 50 minute time limit
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Open powered front trunk
RemarqueVia exterior switch or UI
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Remove fastener covers from bed floor assembly
Remarque14x covers
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Remove bed floor assembly
Remarque10x short bolts, 15mm, 56 Nm, 2x long bolts, 15mm, 46Nm, Lift front edge with trim tool then remove panel, Recommend assistance
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Power off vehicle from center display
RemarqueVerify EPBs are engaged, Select charge port icon to ensure drive state is disengaged then power down vehicle via Controls > Safety > Power Off
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Remove rear underhood apron
Remarque9x clips
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Disconnect first responder loop and MV battery connector
Remarque2x 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
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Verify operation of multimeter
RemarqueSet multimeter to DC voltage, Confirm multimeter is properly measuring voltage by testing MV battery, Touch lightly and do not damage terminals
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Raise vehicle fully and lower lift onto locks
RemarqueSet 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
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Remove rear skid plate
Remarque6x clips, 3x bolts, 15mm, 42 Nm, 5x bolts, 13mm, 28 Nm, 2x bolts, 10mm, 6 Nm
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Position coolant drain container underneath RH rear of HV battery
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Disconnect rear PT supply and RDU supply hoses
Remarque2x spring clip, Plug hoses immediately to prevent excess coolant loss, Allow PCS coolant to drain as much as possible before plugging
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Release PCS coolant header from ancillary floor
Remarque2x bolts, EP10, 6Nm
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Remove coolant drain container from underneath vehicle
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Remove all items from pockets and ensure not wearing metal items
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Inspect HV insulating gloves
RemarqueCheck gloves for damage prior to use, Refer to service document TN-15-92-003, for information on inspecting HV gloves.
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Put on HV insulating gloves and leather over gloves
RemarqueUse 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.
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Verify no HV - Install amp clamp to RDU HV harness
RemarqueVerify 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
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Remove pyro fuse access cover
Remarque4x bolts, E-Torx 5 lobe, 10 Nm
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Remove primary pyro fuse
Remarque2x bolts, 13mm, 5 Nm + 60 Degrees, Support pyro fuse while removing bolts
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Remove secondary pyro fuse
Remarque2x bolts, 13mm, 5 Nm + 60 Degrees, Support pyro fuse while removing bolts
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Release connectors at 2x4 header (AC compressor and Inductive Charger headers)
Remarque2x connectors, Fully release red lock tab, Pull black latch down to release connector
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Release 2x4 header assembly
Remarque4x bolts, 5-lobe 10mm, 6 Nm
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Release drive unit connectors from ancillary headers
Remarque3x connectors, Release blue lock tab, Rotate black latch
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Remove bolts securing HC-Stak HV Headers for LHRDU, FDU, RHRDU from ancillary flange
Remarque6x bolts, 5-lobe 10mm, 10 Nm
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Remove LHRDU, FDU, RHRDU headers from ancillary flange
Remarque3x headers, No tools required, inspect header seals, Replace header if damaged
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Lower vehicle until tires are touching the ground
RemarqueRaise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
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Disconnect ancillary bay MV connector
Remarque1x 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
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Remove bolt securing busbar HV connector lid
Remarque1x bolt, EP10, 9 Nm
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Remove bolts securing HV connector to DC FC header
Remarque2x bolts, 10mm, 9 Nm
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Release HV connector from DC FC header
Remarque1x connector, Use inflatable airbag to suspend busbar assembly above ancillary assembly
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Support HV Busbar assembly
RemarqueSuspend assembly to maintain clearance
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Remove fast charger header doubler
Remarque2x bolts, E10 5 Lobe Torx, 10 Nm
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Release low voltage header
Remarque2x bolts, EP10, 6 Nm
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Release fasteners securing ancillary cover to HV battery
Remarque22x 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
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Remove ancillary cover
RemarqueUse suction cup and maneuver around busbar and tonneau cage
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Remove DC header
Remarque1x 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
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Disconnect PCS MV connector
Remarque1x connector, 1x zip tie, Slide red lock off of lever, Rotate lever to release connector, Remove zip tie as needed
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Release PCS MV harness
Remarque1x bolt, EP10, 6 Nm, 2x clips, Move aside as needed
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Release MV header
Remarque4x datums, 1x edge clip, 1x fir tree clip
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Release HVC connectors
Remarque2x 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
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Release BMB passthrough connectors
Remarque2x connectors, Release connector locks, Depress levers and pull at connector, Do not pull from harness
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Release ACJB LV connector & ACJB to device cluster HV connector
Remarque2x clips, 2x connectors, Release connector locks, Depress levers and pull at connectors, Do not pull at harness, inspect ACJB to DC HV harness part number, if not rev J or newer, replace harness
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Remove MV ancillary harness
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Release HVC harness from PCS
Remarque1x connectors, Release connector lock, Depress lever and pull at connector, Do not pull at harness
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Release device cluster busbar fasteners
Remarque4x bolts, Torx Plus 55, 5Nm + 60 Degrees, Captured bolts with insulated covers
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Remove device cluster assembly fasteners
Remarque4x bolts, E10 5 Lobe Torx, 6Nm
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Remove device cluster from ancillary tray
RemarquePlace 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
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Remove bolts securing PCS
Remarque6x bolts, E10 5-Lobe, 6 Nm, Use E10 5-Lobe socket without magnet, Bolts are captive and will stay attached, Follow fastening order
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Remove PCS from ancillary bay
Remarque1x datum, Maneuver PCS around coolant hoses, Remove plugs as needed
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Remove last mile busbar assembly
Remarque3x bolts, 10mm, 10 Nm, 3x captive bolts, T55, 5 Nm + 60 degrees
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Install last mile busbar assembly
Remarque3x bolts, 10mm, 10 Nm, 3x captive bolts, T55, 5 Nm + 60 degrees
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Install PCS onto ancillary bay
Remarque1x datum, Maneuver PCS around coolant hoses, Plug coolant connections as needed
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Install bolts securing PCS
Remarque6x bolts, E10 5-Lobe, 6 Nm, Use E10 5-Lobe socket without magnet, Bolts are captive and will stay attached, Follow fastening order
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Install device cluster to ancillary tray
RemarqueAlign 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
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Secure device cluster assembly fasteners
Remarque4x bolts, E10 5 Lobe Torx, 6Nm
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Secure device cluster busbar fasteners
Remarque4x bolts, Torx Plus 55, 5Nm + 60 Degrees, Captured bolts with insulated covers
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Perform Hioki measurements from device cluster assembly and busbar bolts
Remarque1x 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
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Secure HVC harness to PCS
Remarque1x connectors, Secure connector lock
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Poistion MV ancillary harness for install
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Secure ACJB LV and HV connectors
Remarque2x clips, 2x connectors, Secure connector locks
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Secure BMB passthrough connectors
Remarque2x connectors, Secure connector locks, Connectors are poke yoked do not force engagement, Ensure locking tabs are facing front of vehicle when connecting
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Secure HVC connectors
Remarque2x 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
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Secure MV header
Remarque4x datums, 1x edge clip, 1x fir tree clip
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Secure PCS MV harness
Remarque1x bolt, EP10, 6 Nm, 2x clips
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Connect PCS MV connector
Remarque1x 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
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Install DC header
Remarque1x connector, 1x tree clip, Slide header on to DC bus links, connector is hidden under the seal, Inspect seal, Replace header if damaged
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Install ancillary cover
RemarqueUse suction cup and maneuver around busbar and tonneau cage
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Secure fasteners of cover to HV battery
Remarque22x 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
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Secure low voltage header
Remarque2x bolts, EP10, 6 Nm
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Secure fast charger header doubler
Remarque2x bolts, E10 5 Lobe Torx, 10Nm
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Clean HV connector contact surface of residual Penetrox
RemarqueAllow 1 minute dry time after removing Penetrox, New busbar comes with Penetrox applied to HV connector
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Clean busbar HV connector contact surface of residual Penetrox
RemarqueAllow 1 minute dry time after removing Penetrox, It is necessary to clean HV connector during re-use of busbar
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Apply Penetrox onto HV connector joints
RemarqueApply 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
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Position busbar connector and lower onto HV header
RemarqueRelease bungee cord
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Install bolts securing charge port busbar kit to HV Header
Remarque2x bolts, 10mm, 9 Nm
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Perform Hioki resistance test at each HV joint from HV busbar lead to bolt head
Remarque2x 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
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Install bolt securing busbar HV connector lid
Remarque1x bolt, EP10, 9 Nm
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Remove leather over gloves and HV insulating gloves
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Connect Ancillary bay MV connector
Remarque1x connector, double locking, Rotate lever into 2nd lock, Perform a pull test to ensure connector engaged correctly
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Raise vehicle fully and lower lift onto locks
RemarqueSet 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
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Secure PCS coolant header to ancillary floor
Remarque2x bolts, EP10, 6Nm
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Position coolant drain container underneath RH rear of HV battery
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Remove one PCS coolant header plugs & connect leak test adapters
Remarque2x spring clips, Leave coolant plugs in supply and return lines, Secure NW22 plug to either coolant header port (Item 6 of kit), Combine NW18 Male testing Couple (Item 5 of kit) to Adapter NW18 180° (Item 1 of kit) and secure to other coolant header port
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Attach coolant pressure tester to pressure fitting adapter
RemarqueConfirm hose is securely screwed tight
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Attach coolant pressure tester to compressed air line
RemarqueMake sure valves are closed on pressure regulator
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Open the regulator valve then slowly adjust regulator to 50 psi
RemarqueUse caution as coolant may spill, Make sure to wear safety glasses
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Open 2nd valve slowly
RemarqueSlowly open valve on pressure regulator and allow pressure to reach specification
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Close the valve and let pressure settle
RemarqueWait 2 minutes for pressure to settle, Record the reading
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Set timer for 2 minutes and select start
RemarqueOnce timer is complete, select Stop Reset
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Perform the coolant pressure leak test
RemarqueWait for another 4 minutes and record the reading. Max delta 0.35 psi. Check coolant hose to see if it is fully seated or not if pressure test fails
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Close both valves
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Remove coolant pressure tester from pressure fitting adapter
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Remove coolant pressure tester adapter from PCS coolant header
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Connect rear PT supply and RDU supply hoses
Remarque2x spring clip, Make sure the locking tabs are fully seated, Perform push-pull-push test
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Remove coolant drain container from underneath vehicle
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Inspect HV insulating gloves
RemarqueCheck gloves for damage prior to use, Refer to service document TN-15-92-003, for information on inspecting HV gloves.
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Put on HV insulating gloves and leather over gloves
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Install LHRDU, FDU, RHRDU headers to ancillary flange
Remarque3x headers, No tools required, inspect header seals, Replace header if damaged
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Secure bolts to HC-Stak HV Headers for LHRDU, FDU, RHRDU to ancillary flange
Remarque6x bolts, 5-lobe 10mm, 10 Nm
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Secure 2x4 header assembly
Remarque4x bolts, 5-lobe 10mm, 6 Nm, Confirm alignment of assembly with fastener openings
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Secure connectors at 2x4 header (AC compressor and Inductive Charger headers)
Remarque2x connectors, Fully engage red lock tab
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Secure drive unit connectors to ancillary headers
Remarque3x connectors, Rotate black latch, Ensure blue locking tab is fully engaged
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Install secondary pyro fuse
Remarque2x bolts, 13mm, 5 Nm + 60 degrees, Support pyro fuse while installing bolts, Bolts may be reused
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Install primary pyro fuse
Remarque2x bolts, 13mm, 5 Nm + 60 degrees, Support pyro fuse while installing bolts, Bolts may be reused
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Perform Hioki resistance test at each HV joint from HV busbar lead to pyro fuse busbar
Remarque4x 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
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Remove leather over gloves and HV insulating gloves
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Install pyro fuse access cover
Remarque4x 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
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Install Mid-aero shield
Remarque6x clips, 3x bolts, 15mm, 70 Nm, 3x bolts, 13mm, 28 Nm, 2x bolts, 10mm, 6 Nm
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Lower vehicle until tires are touching the ground
RemarqueRaise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
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Remove coolant bottle cap
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Install coolant reservoir adaptor cap onto coolant bottle assembly
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Place empty coolant container into front storage area
RemarqueIf frunk is not installed take caution, CFM fan shroud assembly cannot support a full coolant container, Ensure overflow container is empty, Place fender cover over FEM and front fascia
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Fill container with at least 15L of coolant
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Place filled coolant container onto coolant drain & fill cart
RemarqueDo not place container with 15L of coolant on top of CFM fan shroud, Position cart as close as possible to front of vehicle
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Setup coolant refill tool
RemarqueVerify all valves on refill tool are in the closed position, See image for clarity
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Install vacuum refill hose to refill cap on coolant bottle
RemarquePerform push-pull-push test to verify hose is fully installed
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Position overflow hose into empty container
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Place refill hose inside filled coolant container
RemarqueMake sure hose end is fully submerged into coolant
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Connect shop air supply to coolant refill tool
RemarqueIf not already done, Verify refill valve is set to off
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Open air inlet valve to draw a vacuum, Once gauge stabilizes, Fully close valve
RemarqueGauge stabilizes roughly (60-70 cmHg), Vacuum should not drop after the valves are closed
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Slowly open the refill valve to allow coolant to be drawn into the system
RemarqueMake sure hose end of refill hose is fully submerged during entire process
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Once the gauge reads zero, close the coolant refill valve
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Remove shop air supply to coolant refill tool
RemarqueIf not already done, Verify refill valve is set to off
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Remove coolant refill hose from coolant container
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Remove coolant overflow hose from coolant container
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Remove vacuum refill hose from refill cap on coolant bottle
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Remove vacuum refill cap from coolant bottle assembly
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Remove coolant refill tool from vehicle
RemarqueMove coolant drain & fill cart away from vehicle
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Remove coolant container from inside underhood area
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Connect first responder loop and MV battery connector
Remarque2x 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
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Select "Stop Thermal Fill Drain" through UI
RemarqueAllow routine to complete, ensure routine is successful
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Select "Start Coolant Air Purge" using the UI
RemarqueTouch time only, wait until coolant pumps stop running (audible noise), Routine Passed will appear, but pumps will run for 10 minutes, If you start next another routine during this time it will fail, Make sure vehicle is not in "Drive", Routine is still running despite the completed message, Speeds can be monitored in garage under PT Thermal tab, Idle speed = ~1500 RPM, Test will vary speeds from 3500-6500 RPM and actuate valves between SERIES and PARALLEL, Putting vehicle into "Drive" will stop this routine, If speeds hover at 7000 RPM, this indicates the pumps are air locked, perform a vacuum fill, Continue to add coolant and purge until the coolant level reaches between the NOM and MAX Lines on the bottle
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Inspect coolant level and top off as necessary
RemarqueEnsure that the fluid level is at the Max line, Top off fluid as required
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Install coolant bottle cap
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Install rear underhood apron
Remarque9x clips, Adjust windshield seal as required
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Close powered front trunk
RemarqueVia exterior switch or UI
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Install bed floor assembly
Remarque10x short bolts, 15mm, 56 Nm, 2x long bolts, 15mm, 46Nm, Recommend assistance
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Install fastener covers onto bed floor assembly
Remarque14x covers
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Perform Thermal Performance through the UI
RemarqueSelect Thermal > Actions > Test Thermal Performance, click Run, close once routine is completed, if thermal test fails follow toolbox article 206000
- Quitter mode Entretien. Voir Mode Entretien,
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Raise LH front window
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Close LH front door
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Remove vehicle from lift
RemarqueLower rack arms fully and remove them from under vehicle, Remove air suspension from "Jack Mode"