09/09/2022 16:44:24

Forward Junction Box - 1st Generation - 40 Amp Fuse (Remove and Replace)

Correction Code 44200902 Correction Code 44201102

Choose the appropriate procedure based on the vehicle's configuration and date of manufacture:
Informational PurposesAn informational icon, calling your attention
Note
This procedure only applies to vehicles with the 2nd generation High Voltage configuration and 1st generation Forward Junction Box (FJB). On vehicles with the 1st generation High Voltage configuration, the FJB is part of the DCDC converter.

Special tools required for this procedure:

Part Number Description
1058193-00-A Fuse Puller, large (blue)

RWD

Removal

Correction Code 44200902

Warning IconA warning icon, calling your attention to a possibly risky situation
Warning
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 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.
  1. Perform the vehicle HV disablement procedure (refer to procedure).
  2. Remove the underhood storage unit (refer to procedure).
  3. Position the front trunk access service tool.
  4. Disconnect the clips (x4) that attach the coolant hose to the crossbar.
  5. Remove the crossbar from the vehicle.
  6. Release the bolts (x6) that attach the forward junction box cover (torque 6.5 Nm). Remove the cover.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    Before continuing, put on high voltage gloves.
  7. Use a small, insulated screwdriver or similar tool to pry open the cover on the RH side of the FJB.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    Do not use a metallic tool to open the cover.
  8. Use a multimeter to check voltages between:
    • B+ to ground
    • B- to ground
    • B+ and B-
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    If any voltage reading is more than 10V, the contactors are not fully opened. Discontinue this procedure immediately. Contact a Field Service Engineer before performing any further work.
  9. Remove the screws (x3) that attach the plastic cover (torque 3 Nm).
  10. Use the fuse puller to remove the fuse.

Installation

Installation procedure is the reverse of removal.

Dual Motor

Removal

Correction Code 44201102

Warning IconA warning icon, calling your attention to a possibly risky situation
Warning
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 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.
  1. Remove the HV Battery (refer to procedure).
  2. Release the bolts that attach the bracket for powertrain coolant pump 2 (torque 7 Nm). Support the pump.
  3. Disconnect the electrical connector from powertrain coolant pump 2.
  4. Release the bolts (x6) that attach the forward junction box cover (torque 6.5 Nm). Remove the cover.
  5. Use a small screwdriver or similar tool to pry open the cover on the RH side of the FJB
  6. Remove the screws (x3) that attach the plastic cover (torque 3 Nm).
  7. Use the fuse puller to remove the fuse.

Installation

Installation procedure is the reverse of removal.