23/02/2023 05:01:40

HV Rapid Splitter Vehicle Side (Remove and Replace)

Correction Code 44402002

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Warning
Only technicians who have been trained in High Voltage (HV) 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 any time a high voltage cable is handled. Refer to Tech Note TN-15-92-003, "High Voltage Awareness Care Points" for additional safety information.
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Note
This procedure only applies to vehicles built after April 10, 2016.

Special tools required for this procedure:

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Note
The following tools are included in the Rapid Splitter tool kit (Tesla Part Number: 1073594-00-A).
Part Number Description
1073594-00-A Tool Kit, Rapid Splitter

Removal

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Note
The Rapid Splitter is removed as an assembly with the HV cables for the rear drive unit and charger. These HV cables cannot be replaced separately.
  1. Remove the HV battery (refer to procedure).
  2. Remove the rear subframe (refer to procedure).
  3. Remove the 2nd row seat cushion (refer to procedure).
  4. Remove the NVH padding that covers the 2nd row seat frame.
  5. Remove the bolts (x8) that secure the seat frame to the body (torque 26 Nm).
  6. Remove all clips that secure cables to the 2nd row seat frame. Ensure that all cables are reattached to the seat frame upon re-installation.
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    CAUTION
    Do not damage any cables.
  7. Lift up the bottom of the seat frame and support it to provide access to the charger.
  8. Remove and discard the warranty label from the charger access panel.
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    Note
    Components have been removed in this graphic to aid clarity.
  9. Release and discard the fasteners (x11) that secure the charger cover (torque 2 Nm).
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    CAUTION
    Replace all patchbolt(s).
  10. Open the small access door
  11. Remove and discard the bolts (x2) that attach the rapid splitter cables to the charger (torque 6 Nm).
  12. Remove the rapid splitter cables from the charger's HV outlet ports and set aside.
  13. Cut the cable ties from the HV charger cables.
  14. Cut off the HV charger cable locking tabs from the cables.
  15. Remove the HV rapid grommet from the HV rapid mate and slide it off the cables.
  16. Raise the vehicle to comfortable working height to work from below.
  17. Remove the bolts (x2) that attach the LV rapid mate to the body (torque 7 Nm).
  18. Release the clips that attach the HV harness to the LV rapid mate.
  19. Remove the bolts (x2) that attach the HV cable bracket to the vehicle (torque 7 Nm).
  20. Remove the B- HV cable from the Rapid Splitter:
    1. Use a screwdriver or pick to release the retaining collar from the Rapid Splitter. Slide the retaining collar down the HV cable, away from the Rapid Splitter.
    2. Use a pick to release the O-ring from the Rapid Splitter.
    3. Insert the Rapid Splitter socket into the B- cavity and twist it until it is lined up with the locking collar tabs.
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      Note
      If the tape on the HV cable prevents the retaining collar from moving enough to allow access for the socket, remove the tape.
    4. Use the flare nut crowfoot wrench to rotate the socket, removing the cable holder threads from the Rapid Splitter.
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      Note
      The following image shows the wrench removing the B+ cable.
  21. Repeat the previous step on the B+ HV cable.
  22. Carefully remove the spring from the end of the FJB HV B- and B+ cables.
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    Note
    2x spring
  23. Remove the collars from both FJB HV cables.
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    Note
    While holding the cable, slide the collar up and down turning clockwise, once the inner lock is aligned with the outer collar, the collar will slide off the cable.
  24. Remove the seals from both FJB HV cables.
  25. Remove bolts (x3) that attach the HV rapid splitter to the vehicle (torque 8 Nm)
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    Note
    3x bolts, 10mm, 8 Nm
  26. Remove the cable clip that attaches the RDU HV harness to the body.
  27. Remove the Rapid Splitter from the vehicle.

Installation

Installation procedure is the reverse of removal, except for the following:

Tip: If the forward HV cable grommet is difficult to insert into the body, apply P-80 emulsion to the edges of the grommet.
  1. Install the new RDU HV cables B+ and B- after installing the rapid splitter.
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    Note
    Once the cable is locked in, it cannot be removed, so make sure it is routed correctly before locking it in. Push till you hear an audible click.
  2. After inserting the new HV cables into the Rapid Splitter, perform a pull test to ensure that the cables are correctly installed.
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    Note
    The HV cables must be pulled with a force of 150N.
  3. Install the O-rings for the RDU HV cables B+ and B- to the rapid splitter.
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    Note
    Apply P-80 if needed, Use 1/4 long extension to install if necessary. Do not push the O-ring in too far. The collar in the next step will push the O-ring inwards equally if needed.
  4. Install the retaining collar for the RDU HV cables B+ and B- to the rapid splitter.
  5. Install O-rings on the FJB HV B+ and B- cables:
    1. Place the seal installation tool over the terminal.
    2. Apply P-80 emulsion to the seal installation tool.
    3. Push the O-ring along the seal installation tool until it slides onto the HV cable.
    4. Remove the seal installation tool from the HV cable.
    5. Perform steps a-d on the other HV cable.
  6. Install FJB HV B+ and B- cable to rapid splitter
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    Note
    Make sure cables are routed correctly before locking it in. Push till you hear an audible click. Make sure to perform a push-pull-push test to ensure that cables are securely attached.
  7. Install the O-rings for the FJB HV cables B+ and B- to the rapid splitter.
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    Note
    Apply P-80 if needed, Use 1/4 long extension to install if necessary. Do not push the O-ring in too far. The collar in the next step will push the O-ring inwards equally if needed.
  8. Install the retaining collars for the FJB HV cables B+ and B- to the rapid splitter.