2025-11-11

Pack Contactor - High Voltage - Positive (Remove and Install)

Correction code 1630012111 1630012112 1.14 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 ServiceManualFeedback@tesla.com. NOTE: See Personal Protection to make sure wearing proper PPE when performing the below procedure. NOTE: See Ergonomic Precautions for safe and healthy working practices.

  • 2025-11-11: Released new procedure.

Remove

  1. Remove the pyro disconnect. See Pyro Disconnect - HV Battery (Remove and Replace).
  2. Lift the HV Controller up to gain access to the fuse insulator.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    DANGER
    Do not remove HV gloves for the remainder of the procedure.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Set up the seatbelt to hold the HV controller assembly and tray in an upward position.
  3. Disconnect the PCS to DC bus HV connector.
    Informational PurposesAn informational icon, calling your attention
    Note
    Release the locking tab, then disconnect.
  4. Disconnect the PCS logic connector from the PCS.
  5. Disconnect the PCS LV connector from the PCS.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Release the locking tab by pulling upward. A plastic trim tool may be used to help lift the connector upward.
  6. Disconnect the ancillary bay harness connectors (x2) from the positive pack contactor.
  7. Remove the HV PCS to DC bus harness clip from the positive pack contactor.
  8. Remove the HV joint insulators (x2) from the positive HV switch.
  9. Remove and discard the bolt that secures the positive pack contactor to the positive busbar.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 13 mm socket
  10. Remove and discard the nut that secures the positive pack contactor to the rear terminal of module 4.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 13 mm socket
  11. Remove the nuts (x3) that secure the positive pack contactor to the ancillary bay.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 10 mm socket
    Informational PurposesAn informational icon, calling your attention
    Note
    The number of nuts on newer vehicles may vary.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use an insulated magnet to retrieve the nuts after removal.
  12. Remove the positive pack contactor from the ancillary bay.

Install

  1. Position the positive pack contactor to the ancillary bay for installation.
  2. Install the nuts (x3) that secure the positive pack contactor to the ancillary bay.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 10 mm socket
    Informational PurposesAn informational icon, calling your attention
    Note
    The number of nuts on newer vehicles may vary.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use an insulated magnet to position the nuts onto the studs.
  3. Install a new patch bolt to secure the positive pack contactor to the positive busbar. Mark after torquing.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 13 mm socket
    9 Nm (6.6 lbs-ft)
  4. Install a new patch nut to secure the positive pack contactor to the rear terminal of module 4. Mark after torque.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 13 mm socket
    9 Nm (6.6 lbs-ft)
  5. Measure the resistance from the HV joint between the HV battery positive contactor and the center of the HV battery positive terminal. The resistance must be 110μΩ or less.
  6. Measure the resistance at the HV joint of the positive pack contactor to the DC link busbar. The acceptable resistance is between 0.020 mΩ (20 μΩ) and 0.060 mΩ (60 μΩ).
    • If the resistance is less than 0.020 mΩ (20 μΩ), reposition the probes and measure again.
    • If the resistance is greater than 0.060 mΩ (20 μΩ), stop work and escalate a Toolbox session.
  7. Install the ancillary bay harness clip to the positive pack contactor.
  8. Connect the ancillary bay harness connectors (x2) to the positive pack contactor.
  9. Connect the PCS LV connector to the PCS.
    Informational PurposesAn informational icon, calling your attention
    Note
    Push the connector downward, then push the locking tab downward to install the connector. Make sure the connector is fully seated.
  10. Connect the PCS logic connector to the PCS.
  11. Connect the DC bus HV connector to the PCS, then secure the locking tab.
  12. Lower the HV Controller back into place.
  13. Install the pyro disconnect. See Pyro Disconnect - HV Battery (Remove and Replace).