2025-10-28

Spacers and Sleeves - HV Battery (Remove and Replace)

Correction Code See below

  • 2025-10-27: Released procedure from archived information.
Correction Codes:
Correction Code Description FRT
S029716002 Replace 1 HV Battery Spacer 0.42
S039716002 Replace 1 HV Battery Spacer and 1 Sleeve 0.54
S049716002 Replace 2–3 HV Battery Spacers 0.60
S059716002 Replace 2–3 HV Battery Spacers and 2–3 Sleeves 0.90
S069716002 Replace 4–5 HV Battery Spacers 0.78
S079716002 Replace 4–5 HV Battery Spacers and 4–5 Sleeves 1.32
S089716002 Replace 6–7 HV Battery Spacers 0.84
S099716002 Replace 6–7 HV Battery Spacers and 6–7 Sleeves 1.62
S109716002 Replace 8–9 HV Battery Spacers 0.96
S119716002 Replace 8–9 HV Battery Spacers and 8–9 Sleeves 1.98
S129716002 Replace 10–11 HV Battery Spacers 1.08
S139716002 Replace 10–11 HV Battery Spacers and 10–11 Sleeves 2.34
S149716002 Replace 12 HV Battery Spacers 1.14
S159716002 Replace 12 HV Battery Spacers and 12 Sleeves 2.58
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.
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Warning
This procedure can only be performed in designated HV battery repair areas.
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Warning
Put the high voltage "Danger" placard on top of the HV battery to warn others of the potential exposure to high voltage.
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Warning
Only use tools that have been specifically designated for use with this procedure.
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Warning
Obey these safe work practices while performing this procedure:
  • Do not wear headphones.
  • No loud music in HV battery repair areas.
  • Do not perform this procedure alone. Always have a certified assistant on hand, and alert the on-site manager that you will be performing this procedure.
  • Always use 2 people to lift heavy equipment.
  • Absolutely no horseplay.
  • Avoid cluttering the battery rework area. Only tool carts that have tools that are needed for this procedure should be allowed in the battery rework area. Maintain tools and consumables in appropriate cabinets.
  • Label all secondary chemical containers.
  • Dispose of hazardous waste (such as adhesive, coolant, and other chemicals) in appropriate bins or containers.
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Warning
Remove all jewelry (watches, bracelets, rings, necklaces, earrings, ID tags, piercings, etc.) from your person, and all objects (keys, coins, pens, pencils, tools, fasteners, etc.) from your pockets before performing any procedure that exposes you to high voltage.
Warning IconA warning icon, calling your attention to a possibly risky situation
CAUTION
Do not place anything on top of the HV battery, other than the high voltage “Danger” placard.
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CAUTION
Unless otherwise noted, all fasteners are one-time use only. Any removed fasteners must be discarded and replaced with new ones.
Required Parts (HV battery 1.0/1.5)
Part Number Description Quantity
1018551-00-B SHORT HEAD PACK SPACER FASTENER As required
1018552-00-B TALL HEAD PACK SPACER FASTENER As required
1014204-00-C SLEEVE ASSEMBLY As required
Required Parts (HV battery 2.0)
Part Number Description Quantity
1018551-00-C or 1065221-00-A SHORT HEAD PACK SPACER FASTENER As required
1018552-00-C or 1065222-00-A TALL HEAD PACK SPACER FASTENER As required
1014204-00-F ASY,SLEEVE,ALUM ENCLOSURE,MDLS As required
1028556-00-A SEM SELF ETCHING PRIMER GREEN As required
  • Isopropyl Alcohol wipes (1054788-00-A or equivalent)

  • Krytox synthetic non-silicone, low temperature lubricant (1015634-00-A or equivalent)

  • 3M P95 Particulate Respiratory Mask or equivalent
  • Disposable nitrile gloves
Special Tools required for this procedure:
Part Number Description
1051425-00-A SLEEVE INSTALLATION TOOL
1076988-00-A ESD-SAFE VACUUM
1084812-00-A 17 MM HEX BIT SOCKET
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Note
The following tasks are not included in the above correction codes. If any of the following tasks are necessary, add the appropriate correction code(s) separately.
Correction Code Description
16010101/16010201 Battery Assembly (Remove and Install)
16012302 Ski - Side Rail - Battery - LH
16012402 Ski - Side Rail - Battery - RH
16012502 Ski - Side Rail - Battery - LH/RH
16013008 Battery Enclosure - Re-seal - Level 1
16013108 Battery Enclosure - Re-seal - Level 2
S039916005 Remove Corrosion From The HV Battery Cover
16014006 High Voltage Battery Assembly - Battery Blanket (Retrofit)

Spacer Replacement

  1. Connect a laptop with Toolbox 3 to the vehicle. See Toolbox 3 (Connect and Disconnect).
  2. Turn off the power switches by turning the drive rails off.
  3. Check the following values. If any values are outside of specification, stop work and contact Tesla.
    Switches Open
    View Using Value Specification
    Toolbox Isolation Resistance >3000 kOhm
    12V Battery Voltage Approximately 12.6 V
    Touchscreen or Garage DC Link Plus 0 V
    DC Link Minus 0 V
  4. Disconnect the laptop from the vehicle. See Toolbox 3 (Connect and Disconnect).
  5. Remove the HV battery from the vehicle. See HV Battery (RWD/AWD) (Remove and Install).
  6. Identify the location of the spacer(s) to be replaced.
    Figure 1. Front Spacers
    • If the only spacer(s) to be replaced is at the front of the battery, removal of the battery blanket is not required.
    • If any other spacer is to be replaced, remove the battery blanket. See HV Battery Blanket (Remove and Replace).
  7. Perform a HV battery enclosure leak test. See HV Battery Air Leak Test.
  8. Inspect the top and sides of the HV battery for corrosion or damage to the e-coating. If corrosion is present or the e-coating is damaged, remove the corrosion and/or apply primer before continuing this procedure. See HV Battery Cover Corrosion (Remove).
  9. Remove and discard the damaged spacer(s) from the HV battery top cover.
    Figure 2. HV battery 1.0/1.5 shown; HV battery 2.0 similar
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not use power tools to remove the spacers.
    Informational PurposesAn informational icon, calling your attention
    Note
    If a spacer breaks during removal, replace the sleeve. Perform the Sleeve Replacement, HV Battery 1.0/1.5 or Sleeve Replacement, HV Battery 2.0 procedure before continuing to the next step.
    • HV battery 1.0/1.5: The spacers have a right-handed thread.
    • HV battery 2.0: The spacers have a left-handed thread.
  10. Using an ESD-safe vacuum, remove any debris around the exposed spacer hole(s).
  11. Install the correct spacers.
    Figure 3. Short head
    Figure 4. Front and rear spacers
    Figure 5. Tall head
    Figure 6. Middle bolts
    • The front and rear spacers have a short head design (Figures 3 and 4).
    • The middle spacers have a tall head design (Figures 5 and 6).
    Informational PurposesAn informational icon, calling your attention
    Note
    The spacers on HV battery 2.0 may have a groove in the head (Figure 7).
    Figure 7. Groove on spacer of HV battery 2.0 bolts
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    Note
    Do not remove the red tape from the top of the spacer at this time.
  12. Install the new spacers(s).
    • HV battery 1.0/1.5: the spacers have a right-handed thread.
      43 Nm (31.7 lbs-ft)
    • HV battery 2.0: the spacers have a left-handed thread.
      32 Nm (23.6 lbs-ft)
  13. Perform a battery enclosure leak test. See HV Battery Air Leak Test.
  14. If the battery blanket was removed, remove the red tape from the top of each spacer to expose the sealing disks.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not touch the adhesive on top of the spacers after removing the protective tape.
  15. Install the battery blanket, if removed. See HV Battery Blanket (Remove and Replace).
  16. Install the HV battery to the vehicle. See HV Battery (RWD/AWD) (Remove and Install).

Sleeve Replacement, HV Battery 1.0/1.5

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Note
This procedure is for sleeve replacement on HV battery 1.0/1.5 only. For HV battery 2.0, refer to the Sleeve Replacement, HV Battery 2.0 section.
  1. Remove the spacer that is attached to the damaged sleeve. Refer to the Spacer Replacement section.
  2. If a sleeve did not fall from the HV battery when the spacer was removed:
    1. Temporarily place the old spacer into the spacer hole.
    2. Use a rubber mallet to lightly tap the top of the spacer to dislodge the sleeve.
  3. Put a new sleeve onto the sleeve installation tool with the O-rings facing down and the notches aligned so that the sleeve sits flush on the tool.
  4. From the bottom of the HV battery, insert the sleeve into the hole so that the 2 notches on the top of the sleeve align with the 2 notches inside the HV battery. If the notches are not aligned, slowly turn the tool until they are aligned.
  5. Use a small screwdriver to compress the C-clip so that the sleeve can clear the lip on the bottom of the hole.
  6. Make sure that the sleeve is fully inserted into the bottom of the HV battery.
    Figure 8. Sleeve fully inserted
    Figure 9. Sleeve not fully inserted
  7. Repeat steps 1–6 of this section for any additional sleeve(s) that need to be replaced.
  8. Continue with the installation of the spacer. Refer to the Spacer Replacement section.

Sleeve Replacement, HV Battery 2.0

Informational PurposesAn informational icon, calling your attention
Note
This procedure is for sleeve replacement on HV battery 2.0 only. For HV battery 1.0/1.5, refer to the Sleeve Replacement, HV Battery 1.0/1.5 section.
Informational PurposesAn informational icon, calling your attention
Note
On HV battery 2.0, the 2 sleeves located in the rear of the HV battery are integrated into the HV battery enclosure and cannot be replaced. If a rear sleeve requires replacement, discontinue this procedure and return the HV battery to the remanufacturing center.
  1. Remove the spacer that is attached to the damaged sleeve. Refer to the Spacer Replacement section.
  2. Use a 17 mm hex bit socket to unfasten the sleeve.
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    Note
    The sleeve has a right-hand thread.
  3. Remove and discard the sleeve from the HV battery.
    Informational PurposesAn informational icon, calling your attention
    Note
    If the O-ring is stuck on the HV battery enclosure, remove it.
  4. Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    The next steps must be performed in a well-ventilated area while wearing a 3M P95 Particulate Respiratory Mask or equivalent. Refer to all product instructions and warnings for proper application method and safety precautions
    Put on disposable nitrile gloves.
  5. Put the new sleeve on top of a piece of cardboard in a well-ventilated area and spray the sleeve head with a thin coat of SEM Self Etching Primer. Allow the primer to dry for approximately 5 minutes before continuing to the next step.
  6. Apply a small amount of Krytox lubricant on the sleeve seal. Use a disposable glove to spread the lubricant into a thin layer around the sleeve seal.
  7. Install the new sleeve hand-tight on the HV battery enclosure
    Informational PurposesAn informational icon, calling your attention
    Note
    The sleeve has a right-hand thread.
  8. Tighten the sleeve.
    55 Nm (40.6 lbs-ft)
  9. Make sure that the sleeve is fully seated in the HV battery enclosure. Mark the sleeve with an orange paint marker.
  10. Repeat steps 1 to 9 of this section for any additional sleeve(s) that need to be replaced.
  11. Continue with the installation of the spacer. Refer to the Spacer Replacement section.