2025-04-16

Bracket - Skid Plate - Front - HV Battery (Remove and Replace)

Correction code 16102012 3.12 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.

  • 2025-04-17: Updated the spot weld hole saw tool to 2044949-00-A to make sure the drill operation goes no deeper than 2.5mm.
  • 1135762-00-A - KIT, SVC PLUG, COOLING HOSE, MODEL 3
  • 2044949-00-A - KIT, HOLE SAWS FOR SPOT WELDS
  • 1083188-01-B - Digital Multimeter Unit, EXTECH 355
  • 1028556-00-A - SELF ETCHING PRIMER - GREEN 12/CS
Informational PurposesAn informational icon, calling your attention
Note
For EMEA only: This procedure cannot be performed by Service. Sent the HV batteries that need this procedure to Reman.
Informational PurposesAn informational icon, calling your attention
Note
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 safety information.

Remove

  1. Open all doors and lower all windows.
  2. Place the vehicle on the 2-post lift.
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    TIp
    Ensure the vehicle is not charging.
  3. Place the vehicle in Service Mode by using the touchscreen. See Service Mode.
  4. Turn off the A/C and blower motor.
    Informational PurposesAn informational icon, calling your attention
    Note
    Check the temperature icon at the bottom of the screen. If it is grey, A/C is already off. If it is bright, press and hold it for 2 seconds or press it once and press the switch icon in the pop-up menu.
  5. Turn on the drive rail.
    Informational PurposesAn informational icon, calling your attention
    Note
    Sit in the driver seat and step on the brake pedal while key card is placed next to cup holder to turn on the drive rail and power on the vehicle.
  6. On the touchscreen, touch Service Mode > Thermal > Refrigerant System > Start Thermal Fill Drain (Coolant + Refrigerant) and follow the instructions on the touchscreen to complete the routine.
  7. Move both front seats forward.
  8. Remove the underhood storage unit. See Underhood Storage Unit (Remove and Replace).
  9. Perform the vehicle HV disablement procedure. See Vehicle HV Disablement Procedure.
  10. Remove the front skid plate. See Skid Plate - HV Battery - Front (Remove and Replace).
  11. Inspect the front skid plate bracket for damage.
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    Note
    If there is no visible damage to the HV battery structure apart of the front skid plate bracket, continue with further steps.
  12. Position a coolant drain container below the HV battery hose.
  13. Disconnect the RH manifold tube from the LH manifold tube.
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    Note
    Prepare red and 18mm black plugs from Coolant Hose Plug Kit (1135762-00-A). Move the retaining spring clip up into the grooves in the quick release coolant hose connector, and then separate the connectors and plug both ends.
  14. Position the coolant drain container underneath the RH manifold tube inner connection to the HV battery.
  15. Move the RH manifold tube aside and secure it with cable tie.
  16. Remove the coolant drain container from underneath the vehicle.
  17. Remove the bolt that attaches the FDU (Front Drive Unit) HV harness to the FDU.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 10 mm socket
  18. Remove all items from pockets and ensure not wearing metal items.
  19. Inspect and put on the HV insulating gloves and the leather over gloves.
  20. Disconnect the FDU HV harness connector.
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    Note
    Release the locking tab and rotate the release lever up to disengage the connector. Do not force the release lever up to avoid damaging the tabs. Ensure the alignment tabs on the FDU header are not damaged.
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    Note
    When the release lever is fully disengaged, it will be in line with the harness, parallel to the FDU.
  21. Remove the FDU HV harness connector from the FDU, and move it aside.
  22. Disconnect both AC compressor and PTC heater HV harness connectors on the HV battery.
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    Note
    Disengage the red locking tab by pulling it away from the connector, then depress the green tab to release.
  23. Remove the barrel clips (x2) and then remove the ancillary harness bracket from the front of the HV battery.
  24. Wrap the connectors to prevent from debris or metal chips.
  25. Remove the center ski from the HV battery.
  26. Use a spring loaded center punch to mark locations for drilling.
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    Note
    Use a center punch to create a small dimple in the center of each spot weld.
  27. Use spot weld cutters (2044949-00-A) to remove the front skid plate bracket.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use 3/8" size spot weld cutter,Use chiseling technique at high speed to allow the chips to fly out as the cut exits the aluminum, or clean the cutter manually after short drilling, Drill to a depth of no more than the thickness of the Skid Plate Bracket approximately 2.5mm.
  28. Separate the skid plate bracket from the HV battery.
    Informational PurposesAn informational icon, calling your attention
    Note
    When cutter is deep enough, use a 38 mm Scraper or plastic wheel weight removal chisel and light hammer blows to try to separate the skid plate from the battery. If it didn't get off easy, try to drill a little deeper.
  29. Apply masking tape to mark the mating surface.
  30. Use 120 grit sand paper to remove the paint on the mating surface.

Install

  1. Create a stencil of holes for the new skid plate bracket.
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    Note
    Stick the masking tape on the old skid plate bracket along the top edge. Use thin ballpoint pen to mark the holes and the skid plate bracket location on a masking tape piece.
  2. Mark the location of the new holes.
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    Note
    Remove the stencil from the old bracket and apply it to the new one strictly in the same location. Use center punch to create a small dimple in the center of each circle.
  3. Drill holes in the new skid plate bracket.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use chiseling technique at high speed to allow the chips to fly out as the cut exits the hole, or clean the cutter manually after short drilling.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Bench Vise
    • 2044949-00-A - KIT, HOLE SAWS FOR SOPT WELDS
    • Safety Glasses
  4. Remove the masking tape from the HV battery and the skid plate bracket.
  5. Use 120 grit sand paper to clean the future mating surfaces.
  6. Fit the pieces together.
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    Note
    Try the skid plate bracket on the HV battery and check that the flat surfaces fit snugly together.
  7. Use IPA wipes to clean the mating areas, and allow 1 minute to dry.
  8. Apply adhesive.
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    Note
    3M Static Mixing Nozzle for 200 ml cartridges; 3M Scotch-Weld EPX Manual applicator 200ml.
  9. Install the skid plate bracket on the HV battery.
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    Note
    Use the long bolt from the ski plate. Screw it in by hand in the first hole. Apply slight pressure to the bracket using 2 wedges, and then slightly zip tie the wedge as shown on pictures.
  10. Set up the temperature measurement tool.
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    Note
    Set up the Digital multimeter with thermocouple attached to it. Be careful with the polarity of the plug. Press LPF button to change from °F to C°. Turn switch to Temp position. Check if the temperature readings are real. Attach thermocouple to the skid plate.
  11. Use a heat gun to reduce curing time of adhesive.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    When force curing adhesive in a repair area near the High Voltage Battery, do not allow the High Voltage Battery to reach a temperature above 74°C (165°F). Heating the High Voltage Battery above 74°C (165°F) for an extended period could result in injury to personnel and/or damage to the battery. Attach the Bosch digitally adjustable temperature heat gun to the Transmission Jack with the zip ties. Install it facing the skid plate bracket 10 cm from it curing▪ 7 days at 23 ± 2 °C▪ 2 hours at 65 ± 2 °C.
  12. Allow 2 hours for the adhesive to cure.
  13. Cut the zip tie and remove the wedges, and then remove the bolt from the center ski cover first hole.
  14. Use self etching primer to touch up the bare metal spots.
  15. Install the center ski to the HV battery.
  16. Remove all items from pockets and ensure not wearing metal items
  17. Inspect and put on the HV insulating gloves and the leather over gloves.
  18. Remove the masking tape from the connectors.
  19. Install the barrel clips (x2) to install the ancillary harness bracket to the front of the HV battery.
  20. Connect both AC compressor and PTC heater HV harness connectors on the HV battery.
    Informational PurposesAn informational icon, calling your attention
    Note
    After the connector is seated and there is an audible click, engage the second lock by pressing towards the connector.
  21. Install the FDU HV harness connector to the FDU.
    Informational PurposesAn informational icon, calling your attention
    Note
    Install the HV connector lever lock to the FDU HV cable connector. Align the connector to the FDU, and then remove the HV connector lever lock before fully latching the connector. Use one hand to support the connector while the other latching the locking tab. Once installed, verify that the latch is not damaged and fully secured in the latched position.
  22. Remove the HV insulating gloves.
  23. Install the bolt that attaches the FDU HV harness to the FDU.
    10 Nm (7.4 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 10 mm socket
  24. Cut the cable tie and set free the RH manifold tube.
  25. Position the coolant drain container underneath the RH manifold tube inner connection to the HV battery.
  26. Install the RH manifold tube to the front of the HV battery.
    Informational PurposesAn informational icon, calling your attention
    Note
    Remove the plugs from both end, and then join the quick release coolant hose connectors. Push the retaining spring clip to the place. Perform a push-pull-push test to make sure the hose is fully seated.
  27. Position the coolant drain container below the HV battery hose.
  28. Install the RH manifold tube to the LH manifold tube.
    Informational PurposesAn informational icon, calling your attention
    Note
    Remove the plugs from both ends, and then join the quick release coolant hose connectors. Push the retaining spring clip to the place. Perform a push-pull-push test to make sure the hose is fully seated.
  29. Remove the coolant drain container from underneath the vehicle.
  30. Install the front skid plate. See Skid Plate - HV Battery - Front (Remove and Replace).
  31. Remove coolant bottle cap, inspect the coolant level and top off as necessary.
  32. Connect the LV battery power. See 12V/LV Power (Disconnect and Connect).
  33. Remove the 2nd row seat cushion. See Seat Cushion - Lower - 2nd Row (Remove and Replace).
  34. Turn on the drive rail.
    Informational PurposesAn informational icon, calling your attention
    Note
    Sit in the driver seat and step on the brake pedal while key card is placed next to cup holder to turn on the drive rail and power on the vehicle.
  35. On the touchscreen, touch Service Mode > Thermal > Refrigerant System > Stop Thermal Fill Drain > Run, and allow the routine to complete.
  36. On the touchscreen, touch Coolant System > Coolant Purge > Run, and allow the routine to complete.
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    Note
    • The routine will last for a while after the stop message displays. The coolant pumps are audible.
    • The test lasts for approximately 10 mins. Do not start another routine during this time.
    • Make sure that the vehicle is not in Drive. Putting the vehicle into Drive will stop this routine.
    • The speed in the test varies from 3500-6500 RPM (idle speed = ~1500 RPM) and the actuated valve varies between SERIES and PARALLEL.
    • If the speed hovers at 7000 RPM, it indicates the pumps are air locked. Perform the vacuum fill again. Continue to add the coolant and purge until the coolant level reaches between the NOM and MAX Lines on the bottle.
  37. Inspect the coolant level, top off as necessary, and then install the coolant bottle cap.
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    Note
    Ensure that the coolant level is at the "Max" line.
  38. Install the underhood storage unit. See Underhood Storage Unit (Remove and Replace).
  39. Exit Service Mode. See Service Mode.
  40. Raise all windows and close all doors.
  41. Remove the lift arms from below the vehicle.