23/02/2023 05:01:40
HV Rapid Splitter Vehicle Side (Remove and Replace)
Correction Code 44402002
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.
Note
This procedure only applies to vehicles built after April 10, 2016.
Special tools required for this procedure:
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
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.
- Remove the HV battery (refer to procedure).
- Remove the rear subframe (refer to procedure).
- Remove the 2nd row seat cushion (refer to procedure).
-
Remove the NVH padding that covers the 2nd row seat frame.
-
Remove the bolts (x8) that secure the seat frame to the body (torque 26 Nm).
-
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.
CAUTIONDo not damage any cables.
- Lift up the bottom of the seat frame and support it to provide access to the charger.
-
Remove and discard the warranty label from the charger access panel.
NoteComponents have been removed in this graphic to aid clarity.
-
Release and discard the fasteners (x11) that secure the charger cover (torque 2 Nm).
CAUTIONReplace all patchbolt(s).
-
Open the small access door
-
Remove and discard the bolts (x2) that
attach the rapid splitter cables to the charger (torque 6 Nm).
-
Remove the rapid splitter cables from
the charger's HV outlet ports and set aside.
-
Cut the cable ties from the HV charger
cables.
-
Cut off the HV charger cable locking
tabs from the cables.
-
Remove the HV rapid grommet from the
HV rapid mate and slide it off the cables.
- Raise the vehicle to comfortable working height to work from below.
-
Remove the bolts (x2) that attach the
LV rapid mate to the body (torque 7 Nm).
-
Release the clips that attach the HV
harness to the LV rapid mate.
-
Remove the bolts (x2) that attach the
HV cable bracket to the vehicle (torque 7 Nm).
-
Remove the B- HV cable from the Rapid
Splitter:
- Repeat the previous step on the B+ HV cable.
-
Carefully remove the spring from the
end of the FJB HV B- and B+ cables.
Note2x spring
-
Remove the collars from both FJB HV
cables.
NoteWhile 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.
-
Remove the seals from both FJB HV
cables.
-
Remove bolts (x3) that attach the HV
rapid splitter to the vehicle (torque 8 Nm)
Note3x bolts, 10mm, 8 Nm
-
Remove the cable clip that attaches
the RDU HV harness to the body.
- 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.
-
Install the new RDU HV cables B+ and
B- after installing the rapid splitter.
NoteOnce 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.
-
After inserting the new HV cables into
the Rapid Splitter, perform a pull test to ensure that the cables are correctly
installed.
NoteThe HV cables must be pulled with a force of 150N.
-
Install the O-rings for the RDU HV
cables B+ and B- to the rapid splitter.
NoteApply 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.
-
Install the retaining collar for the
RDU HV cables B+ and B- to the rapid splitter.
-
Install O-rings on the FJB HV B+ and
B- cables:
-
Install FJB HV B+ and B- cable to
rapid splitter
NoteMake 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.
-
Install the O-rings for the FJB HV
cables B+ and B- to the rapid splitter.
NoteApply 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.
-
Install the retaining collars for the
FJB HV cables B+ and B- to the rapid splitter.