HV Pack Contactor (Remove and Replace)
Correction code 1630010102 FRT 1.02 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 LaborTimeFeedback@tesla.com. NOTE: See Personal Protection to make sure wearing proper PPE when performing the below procedure.
- 2024-09-10: Added a step to clean the negative pack contactor before installation.
- 1057605-00-A Skt, 1/4" Dr, 10mm, Univ, HV Insu
- 1076928-00-A Test Probes - Hioki 9461
- 1453448-01-A Kit Digital Multimeter Set EXTECH 335
- 1076927-00-A Hioki tester
High Voltage Awareness Care Pointsfor additional safety information.
Description | Torque Value | Recommended Tools | Reuse/Replace | Notes |
---|---|---|---|---|
Patch bolt that attaches the negative pack contactor to the DC link busbar joint |
|
|
Replace | |
Patch nut that attaches negative pack contactor to the HV battery tall silicon terminal |
|
|
Replace | |
Nuts that attach the negative pack contactor to the ancillary bay |
|
|
Reuse |
High Voltage Awareness Care Pointsfor additional safety information.
Remove
- Remove the pyrotechnic battery disconnect. See Pyro Disconnect - HV Battery (Remove and Replace).
- Remove the ancillary bay harness clip around the negative pack contactor area.
- Remove the HV joint insulators (x2) from the negative pack contactor.
-
Remove and discard the patch bolt that
attaches the negative pack contactor to the DC link busbar joint.
Tip: Use of the following tool(s) is recommended:
- Insulated
tools:
- 13 mm socket
- Ratchet/torque wrench
- 6 in extension
- Electrical Protective Gloves
- Paint Pen
- Ratchet/torque wrench
- Insulated
tools:
-
Remove and discard the patch nut that
attaches negative pack contactor to the HV battery tall silicon terminal.
Tip: Use of the following tool(s) is recommended:
- Insulated
tools:
- 13 mm socket
- Ratchet/torque wrench
- 6 in extension
- Electrical Protective Gloves
- Ratchet/torque wrench
- Paint Pen
- Insulated
tools:
-
Remove the nuts (x3) that attach the
negative pack contactor to the ancillary bay.
NoteUse insulated magnet to retrieve the nuts after removal. The number of nuts on newer vehicles may vary.Tip: Use of the following tool(s) is recommended:
- Insulated
tools:
- Ratchet/torque wrench
- 6 in extension
- Magnetic pick up tool
- 1/4in Dr. Universal Joint x 10mm - 1057605-00-A
- Electrical Protective Gloves
- Paint Pen
- Ratchet/torque wrench
- Insulated
tools:
- Remove the guide pins (x2) to remove the negative pack contactor from the ancillary bay.
Install
- Use an IPA wipe to clean the negative pack contactor.
- Position the negative pack contactor to the ancillary bay for installation, and then install the guide pins (x2).
-
Install the nuts (x3) that attach the
negative pack contactor to the ancillary bay, and mark after torque.NoteUse insulated magnet as needed to position the nuts onto the studs. The number of nuts on newer vehicles may vary.Tip: Use of the following tool(s) is recommended:
- Insulated
tools:
- Ratchet/torque wrench
- 6 in extension
- Magnetic pick up tool
- 1/4in Dr. Universal Joint x 10mm - 1057605-00-A
- Electrical Protective Gloves
- Paint Pen
- Ratchet/torque wrench
- Insulated
tools:
-
Install the patch bolt that attaches
the negative pack contactor to the DC link busbar joint, and mark after torque.Tip: Use of the following tool(s) is recommended:
- Insulated
tools:
- 13 mm socket
- Ratchet/torque wrench
- 6 in extension
- Electrical Protective Gloves
- Paint Pen
- Ratchet/torque wrench
- Insulated
tools:
-
Install the patch nut that attaches
negative pack contactor to the HV battery tall silicon terminal.Tip: Use of the following tool(s) is recommended:
- Insulated
tools:
- 13 mm socket
- Ratchet/torque wrench
- 6 in extension
- Electrical Protective Gloves
- Ratchet/torque wrench
- Paint Pen
- Insulated
tools:
-
Perform Hioki impedance test at the HV
joint of the negative pack contactor to the negative DC link busbar.
- If the resistance is greater than 0.060 mΩ (60 μΩ), there is too much resistance in the High Voltage joint. Remove the fastener, clean areas with isopropyl alcohol, install fastener back and test again.
- If the resistance is less than 0.020 mΩ (20 μΩ), reposition the probes and measure again.
-
Perform Hioki impedance test at the
negative pack contactor to module 1 rear terminal
NoteThe acceptable impedance is 110 μΩ or less.
- Install the HV joint insulators (x2) to the negative pack contactor.
- Connect the ancillary bay harness connectors (x2) to the negative pack contactor.
- Install the ancillary bay harness clip around the negative pack contactor area.
- Install the pyrotechnic battery disconnect. See Pyro Disconnect - HV Battery (Remove and Replace).
- Raise all windows and close all doors.