31/05/2024 12:50:13

HV Rapid Splitter Vehicle Side (Remove and Replace)

Correction Code 44400102

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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.

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. Position the vehicle on a lift, but do not raise the vehicle at this time.
  2. Open the driver's door, hood, both rear doors, and the liftgate.
  3. Remove the HEPA filter. See Filter - HEPA (Remove and Replace).
  4. Remove the LH rear trunk side trim. See Trim - Rear Trunk - Side - LH (Remove and Replace).
  5. Perform Vehicle HV Disablement Procedure. See Vehicle HV Disablement Procedure
  6. Remove the charger. See Charger (Remove and Replace).
  7. Remove both rear wheels. See Wheels - Axle Set (Remove and Install).
  8. Remove the HV battery. See HV Battery (AWD) (Remove and Install).
  9. Remove the rear subframe. See Subframe Assembly - Rear (Remove and Install).
  10. Lower the vehicle to gain access to the interior.
  11. Remove the Lava tube foam piece covering the charger cable.
  12. Feed charger cables out from the hole in the body.
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    Note
    Push HV charger harness grommet out of its fitting.
  13. Raise vehicle to a comfortable working height.
  14. Remove the bolts (x2) that attach the LV rapid mate to the body (torque 7 Nm).
  15. Release the clips that attach the HV harness to the LV rapid mate and set the LV rapid mate aside.
  16. Remove and discard the bolts (x2) that secure the HV cable bracket to the body of the vehicle (torque 7 Nm).
  17. 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. Carefully cut through the O-ring and remove it from the HV cable.
    4. 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.
    5. 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.
    6. Carefully remove the spring from the end of the HV cable.
    7. While holding the metal piece in place, twist the plastic cap until the tabs and grooves are aligned. Once the tabs and grooves are aligned, the collar can be removed from the HV cable.
      Twist plastic cap Tabs highlighted Remove collar
    8. Inspect the plastic cap for damage. Replace if damaged.
    9. Discard the retaining spring.
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      Note
      The retaining spring is a one-time use part. Do not reuse the retaining spring.
    10. Place an HV cover on the end of the HV cable.
  18. Repeat the previous step on the B+ HV cable.
    Tip: Remove the cable tie that holds the HV cables together. Move the B- HV cable out of the working area for more access to the B+ HV cable.
  19. Remove the bolts (x3) that attach the HV rapid splitter to the vehicle (torque 8 Nm).
  20. Remove the cable clip that attaches the RDU HV harness to the body.
  21. Remove the nuts (x3) that secure the HV cable bracket to the studs on the body of the vehicle (torque 4 Nm).
    Informational PurposesAn informational icon, calling your attention
    Note
    Components have been removed in this graphic to aid clarity.
  22. Remove the Rapid Splitter from the vehicle.

Installation

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. Position the HV rapid splitter to the vehicle for installation.
  2. Install the bolts (x3) that attach the HV rapid splitter to the vehicle (torque 8 Nm).
  3. Install the new RDU HV cables into the Rapid splitter. Push the cables until a "click" is heard, and then perform a push-pull-push test.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure cable routing is accounted for before installing, as they cannot be removed after they are installed.
  4. Use a force gauge to perform a 150 N pull test on the B+ and B- RDU HV cables.
  5. Install the B+ and B- RDU HV cable O-rings into the Rapid splitter.
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    Note
    Make sure the O-rings are evenly seated, as pictured.
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    Note
    The retaining collars, installed in the next step, will push the O-rings to the correct depth.
    Tip: Use a 1/4 inch extension to help seat the O-ring. If needed, apply P-80 to aid with O-ring installation.
  6. Use snap ring pliers to install the retaining collars on the B+ and B- RDU HV cables.
  7. Install the cable clip that attaches the RDU HV harness to the body.
  8. Install the O-ring on the HV harness O-ring installation tool (found in the Rapid splitter tool kit), and then use the tool to install O-rings on the B+ and B- FJB HV cables.
  9. Install the FJB HV cables into the Rapid splitter. Push the cables until a "click" is heard, and then perform a push-pull-push test.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure cable routing is accounted for before installing, as they cannot be removed after they are installed.
  10. Install the B+ and B- FJB HV cable O-rings into the Rapid splitter.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure the O-rings are evenly seated, as pictured.
    Informational PurposesAn informational icon, calling your attention
    Note
    The retaining collars, installed in the next step, will push the O-rings to the correct depth.
    Tip: Use a 1/4 inch extension to help seat the O-ring. If needed, apply P-80 to aid with O-ring installation.
  11. Use snap ring pliers to install the retaining collars on the B+ and B- FJB HV cables.
  12. Install the bolts (x2) that secure the HV cable bracket to the body of the vehicle (torque 7 Nm).
  13. Install the clips that attach the HV harness to the LV rapid mate.
  14. Install the bolts (x2) that attach the LV rapid mate to the body (torque 7 Nm).
  15. Lower the vehicle to a comfortable working height.
  16. Install the charger HV cable grommet on the Rapid splitter.
  17. Install the new charger B- HV cable into the Rapid splitter.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure cable routing is accounted for before installing, as they cannot be removed after they are installed.
  18. Install the B- charger HV cable O-ring into the Rapid splitter.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure the O-ring are evenly seated.
    Informational PurposesAn informational icon, calling your attention
    Note
    The retaining collars, installed in the next step, will push the O-rings to the correct depth.
    Tip: Use a 1/4 inch extension to help seat the O-ring. If needed, apply P-80 to aid with O-ring installation.
  19. Use snap ring pliers to install the retaining collar on the B- charger HV cable.
  20. Install the new charger B+ HV cable into the Rapid splitter.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure cable routing is accounted for before installing, as they cannot be removed after they are installed.
  21. Install the B+ charger HV cable O-ring into the Rapid splitter.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure the O-ring are evenly seated.
    Informational PurposesAn informational icon, calling your attention
    Note
    The retaining collars, installed in the next step, will push the O-rings to the correct depth.
    Tip: Use a 1/4 inch extension to help seat the O-ring. If needed, apply P-80 to aid with O-ring installation.
  22. Use snap ring pliers to install the retaining collar on the B+ charger HV cable.
  23. Feed charger cables out from the hole in the body.
    Informational PurposesAn informational icon, calling your attention
    Note
    Push HV charger harness grommet out of its fitting.
  24. Install the nuts (x3) that secure the HV cable bracket to the studs on the body of the vehicle (torque 4 Nm).
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    Note
    Components have been removed in this graphic to aid clarity.
  25. Lower vehicle to comfortable working height.
  26. Route charger cables near their home location.
  27. Install new foam gasket onto the charger.
  28. Place charger into vehicle so HV cables can be installed.
  29. Remove dummy plug or tape covering the opening for the charger access panel.
  30. Release tabs and open small access door.
  31. Install rapid splitter cables into charger HV outlet.
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    Note
    Make sure black tabs are secure, insert cables into correct cavity on charger, shorter positive cable closest to access panel, longer negative cable furthest from access panel.
  32. Install fasteners (x2) securing rapid splitter cables to charger (torque 6 Nm).
  33. Install charger onto the upper mounting brackets and torque bolts (X2) (torque 9 Nm).
  34. Install LH trunk tie down bracket.
  35. Install ground strap to charger.
  36. Install ground strap to D-pillar.
  37. Remove PTC dummy plug.
  38. Secure PTC harness barrel clips to D-pillar and charger bolt studs.
  39. Connect rear PTC heater.
  40. Release tabs and open small access door.
  41. Release tabs and open large access door.
  42. Install HV charge port cables into charger and secure tabs.
  43. Install nuts securing charge port cables.
  44. Install bolts securing HV cables from the rapid splitter.
  45. Close large and small access door.
  46. Install the new bolts (X12) to secure the charger access panel (torque 2 Nm).
  47. Clean area around charger access panel prior to installation of new warranty label.
  48. Install new warranty label.
  49. Connect coolant inlet hose to charger.
  50. Remove hose clamp pliers from CHG inlet hose.
  51. Install HV charger cable grommet.
  52. Install the Lava tube foam piece covering the charger cable.
  53. Install the rear subframe. See Subframe Assembly - Rear (Remove and Install).
  54. Install the HV battery. See HV Battery (AWD) (Remove and Install).
  55. Install both rear wheels. See Wheels - Axle Set (Remove and Install).
  56. Install the charger. See Charger (Remove and Replace).
  57. Perform the vehicle HV disablement procedure, checking at the charger. See Vehicle HV Disablement Procedure.
  58. Install the LH rear trunk side trim. See Trim - Rear Trunk - Side - LH (Remove and Replace).
  59. Perform a coolant air purge (refer to procedure).
  60. Install the HEPA filter. See Filter - HEPA (Remove and Replace).
  61. Close the driver's door, hood, both rear doors, and the liftgate.
  62. After installation is complete, calibrate the falcon doors from the MCU.
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    Note
    Falcon door calibration is required after each 12V and First Responder Loop disconnection.
  63. Perform a four wheel alignment check (refer to procedure).
  64. Make sure that the vehicle's charging system functions as intended.