2025-10-22

Shunt - HV Battery (Remove and Replace)

Correction code 16303602 1.26 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. See Ergonomic Precautions for safe and healthy working practices.

  • 1057602-00-A Ratchet, 1/4" Sq Dr, HV Insulated
  • 1057603-00-A Ext Bar, Wobble, 1/4" Dr, HV Insulated
  • 1057606-00-A Skt, 1/4" Sq Dr, 13mm, HV Insulated
  • 1076927-00-A Resistance meter, microohm, Hioki RM 3548
Warning IconA warning icon, calling your attention to a possibly risky situation
Warning

Only technicians who have completed all required certification courses are permitted to perform this procedure. Tesla recommends third party service provider technicians undergo equivalent training before performing this procedure. For more information on Tesla Technician requirements, or descriptions of the subject matter for third parties, see HV Certification Requirements. 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.

  • 2023-07-06: Added a video in step 7 of Install part.
  • 2025-10-20: Updated the routine for different shunt types.

Remove

  1. Disconnect 12V power. See 12V/LV Power (Disconnect and Connect).
  2. Perform Vehicle HV Disablement Procedure. See Vehicle HV Disablement Procedure.
  3. Remove the ancillary bay cover. See Cover - Ancillary Bay (Remove and Replace).
  4. Remove the pyrotechnic battery disconnect. See Pyrotechnic Battery Disconnect (Remove and Replace).
  5. Disconnect the electrical harness from the shunt connector.
  6. Unhook the electrical harness from the shunt insulator, and then remove the shunt insulator, if installed.
  7. Remove and discard the bolt that attaches the shunt to the busbar.
  8. Remove the shunt from the vehicle.

Install

  1. Perform a zero adjust of the Hioki resistance meter in preparation to measure resistances later in this procedure. See Resistance Meter (Zero Adjust).
  2. Write down new shunt bar resistance and part number as printed on the new shunt.
    Informational PurposesAn informational icon, calling your attention
    Note
    The resistance is in the range of 20000 to 30000 nano Ohms. For example, "R:25819nΩ" is a resistance of 25819 nano Ohms, so record "25819".
  3. Use an IPA wipe to clean the HV mating surfaces of the shunt, busbar, and the pyrotechnic battery disconnect.
  4. Install the shunt to the busbar, and then install and hand-tighten a new bolt to attach the shunt to the busbar.
  5. Measure the voltage across the pyrotechnic battery disconnect mount points, and then install the pyrotechnic battery disconnect. See Pyrotechnic Battery Disconnect (Remove and Replace).
  6. Tighten the bolt that attaches the shunt to the busbar, and then mark the bolt with a paint pen after it is torqued.
    9 Nm (6.6 lbs-ft)
  7. Use the Hioki resistance meter to measure the resistance of the HV joint between the shunt and the adjacent busbar.
    Informational PurposesAn informational icon, calling your attention
    Note
    The maximum acceptable resistance is 0.045 mΩ (45 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
    Figure 1. Generic Measurement - Actual busbars and fasteners might appear different
  8. Install the shunt insulator, if previously removed.
  9. Connect the electrical harness to the shunt connector, and then hook the electrical harness to the shunt insulator, if installed.
  10. Install the pyrotechnic battery disconnect shunt insulator(s).
    Figure 2. 1st Generation
    Figure 3. 2nd Generation
  11. Remove the logic connector cap from the high voltage controller connector.
  12. Install the ancillary bay cover. See Cover - Ancillary Bay (Remove and Replace).
  13. Use a paint pen to write the 5-digit new shunt resistance value from step 2 and the date onto the ancillary bay cover.
    Informational PurposesAn informational icon, calling your attention
    Note
    For example, "Shunt res 25819, 05/25/2021".
  14. Connect 12V/LV power. See 12V/LV Power (Disconnect and Connect).
  15. Connect a laptop with Toolbox 3 to the vehicle. See Toolbox 3 (Connect and Disconnect).
  16. SelectHigh Voltage > Procedures > Shunt Replacement > Write Shunt Data and WRITE operation, enter the shunt bar resistance value previously recorded in step 2, and select corresponding shunt type based on the Part number. Click Run and allow the routine to complete.
    Informational PurposesAn informational icon, calling your attention
    Note
    Shunt types includes Vishay whose part number looks like 2084224-XX-X and Cyntec whose part number looks like 1078835-XX-X or 1588177-XX-X.
  17. Disconnect the laptop from the vehicle. See Toolbox 3 (Connect and Disconnect).