2026-04-03

HV Battery (AWD) (Remove and Install)

Correction Code 16010201

  • 2026-04-02: Updated LH/RH rear shear plate images and fasteners for clarity purposes.
  • 2024-08-16: Added note stating it is not necessary to perform HV disablement.
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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.
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Warning
If the vehicle has air suspension, activate "Jack" mode on the touchscreen before raising and supporting the vehicle.
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Warning
Before starting this procedure, make sure that all bolts that attach the battery to the vehicle are installed on the vehicle. Failure to check for missing bolts might result in the battery pack to become loose unexpectedly, and might injure a technician.
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Note
Use a cordless electric drill with a 3/8 in drive adapter and an 3/8 in drive air ratchet wrench to perform this procedure. Do not use an impact wrench to remove battery fasteners.
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Note
This procedure is intended to be performed by 2 technicians.

Special tools required for this procedure:

Supplier Part Number Description
Tesla 1020566-00-E BATT MAN LIFT TABLE - MDLS

Removal

  1. Open LH front door.
  2. Raise and support vehicle.
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    Note
    Set air suspension to "Jack Mode" Via Controls > Service > ''Jack Mode''.
  3. Open hood.
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    Note
    Via center display > Controls > Front Trunk.
  4. Remove underhood aprons.
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    Note
    4x aprons.
  5. Remove frunk carpet.
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    Note
    2x connectors.
  6. Remove underhood storage unit.
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    Note
    10x bolts, 10mm, 4 Nm, 10x bolts, 10mm, 7 Nm.
  7. Remove HEPA filter.
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    Note
    Lift up from bottom and pull out.
  8. Power down vehicle using MCU.
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    Note
    Via Controls > Safety > ''Power off".
  9. Disconnect 12V negative terminal.
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    Note
    1x nut, 10mm, 5 Nm.
  10. Disconnect first responder loop.
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    Note
    Do not perform HV disablement. It is not required when performing an HV battery remove and install.
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    Note
    1x connector, push to release.
  11. Raise vehicle fully and lower onto locks.
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    Note
    Set vehicle to comfortable working height, Make sure there's an audible click of the locks on both sides before lowering, otherwise vehicle may tilt to the side.
  12. Remove LH rear shear plate.
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    Note
    3x screws, T25, 6 Nm, 35 Nm, 1x bolt, 10mm, 4 Nm, 2x push clips, 1x nylon nut, 15mm, Discard nylon nut after removal.
  13. Remove RH rear shear plate.
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    Note
    3x screws, T25, 6 Nm, 35 Nm, 1x bolt, 10mm, 4 Nm, 2x push clips, 1x nylon nut, 15mm, Discard nylon nut after removal.
  14. Remove mid aero shield.
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    Note
    20x bolts, 10mm, 4 Nm, 2x push clips.
  15. Remove front bash plate extrusion.
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    Note
    2x patch bolts, T30, 16 Nm.
  16. Remove LH ski side covers.
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    Note
    14x push clips, 3x covers.
  17. Remove RH ski side covers.
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    Note
    14x push clips, 3x covers.
  18. Loosen four center bolts securing HV battery.
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    Note
    4x patch bolts, E12, 38 Nm, Discard after removal.
  19. Remove four center bolts securing HV battery.
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    Note
    4x patch bolts, E12, 38 Nm, Discard after removal.
  20. Position battery table beneath vehicle.
  21. Lower vehicle to table.
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    Note
    Recommend assistance, Align table to vehicle and raise casters to level table if necessary.
  22. Loosen remaining eight center bolts securing HV battery.
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    Note
    8x patch bolts, E12, 38 Nm, Discard after removal.
  23. Remove remaining eight center bolts securing HV battery.
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    Note
    8x patch bolts, E12, 38 Nm, Discard after removal.
  24. Loosen front four HV battery bolts.
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    Note
    4x patch bolts, 13mm, 30 Nm, Discard after removal.
  25. Remove front four HV battery bolts.
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    Note
    4x patch bolts, 13mm, 30 Nm, Discard after removal.
  26. Loosen 21mm bolts securing front of HV battery.
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    Note
    2x bolts, 21mm, 115 Nm, Discard after removal.
  27. Remove 21mm bolts securing front of HV battery.
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    Note
    2x bolts, 21mm, 115 Nm, Discard after removal.
  28. Loosen LH rocker bolts.
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    Note
    8x patch bolts, 13mm, 55 Nm, Discard after removal.
  29. Remove LH rocker bolts.
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    Note
    8x patch bolts, 13mm, 55 Nm, Discard after removal.
  30. Loosen RH rocker bolts.
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    Note
    8x patch bolts, 13mm, 55 Nm, Discard after removal.
  31. Remove RH rocker bolts.
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    Note
    8x patch bolts, 13mm, 55 Nm, Discard after removal.
  32. Raise vehicle and remove battery table.
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    Note
    Recommend assistance.
  33. Move battery away from vehicle.
  34. Place an HV Danger placard on top of the HV battery and place a barrier around the working area.
  35. Remove all items from pockets and ensure not wearing metal items.
  36. Inspect HV insulating gloves.
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    Note
    Check gloves for damage prior to use, Refer to service document TN-15-92-003 R1, for information on inspecting HV gloves https://service.teslamotors.com/protected-doc/ServiceBulletins/External/TN/TN-15-92-003_High_Voltage_Awareness_Care_Points_R1.pdf.
  37. Put on HV insulating gloves and leather over gloves.
  38. Use a multimeter to check voltages at the Rapid Splitter.
    • B+ to ground
    • B- to ground
    • B+ to B-
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    If any voltage reading is more than 10V, continue to hold the probes to the test points to drop the voltage to 10V. If the voltage does not drop, contact a Field Service Engineer before performing any further work.
  39. Check voltage on HV Rapid Mate.
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    Note
    B+ to ground, B- to ground, and B+ to B-, If any voltage reading is more than 10V, the pack contactors are not fully opened, Contact Engineering for support.
  40. Insert the high voltage RapidMate cover (1038478-00-A) and the low voltage RapidMate cover (1028325-00-A) into the high and low voltage RapidMates.
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    Note
    If the covers are not available, use 3M 2480S Masking Tape (2" wide) or 3M 471 Red Vinyl Tape (2” wide) to seal the RapidMates.
  41. Remove leather over gloves and HV insulating gloves.

Installation

  1. Raise vehicle for positioning of HV battery.
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    Note
    Set vehicle to comfortable working height, Make sure there's an audible click of the locks on both sides before lowering, otherwise vehicle may tilt to the side.
  2. Put on HV insulating gloves and leather over gloves, and do not remove them until the HV battery is mated with the vehicle.
  3. Remove covers or tape from LV and HV Rapid Mates.
  4. Position HV battery underneath vehicle.
  5. Lower vehicle onto pack.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    There may be residual high voltage at the RapidMate connector which might arc when inspecting the connection there.
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    Note
    Align Rapid Mate connections before lowering fully, Recommend assistance.
  6. Remove leather over gloves and HV insulating gloves.
  7. Install front bolts securing HV battery to body with battery powered drill .
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    Note
    4x patch bolts, 13mm, 30 Nm, Install new patch bolts, Do not over tighten bolts, Torque at later step.
  8. Install outer front bolts securing HV battery to body with battery powered drill .
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    Note
    2x bolts, 21mm, 115 Nm, Install new bolts, Do not over tighten bolts, Torque at later step.
  9. Install outer center bolts securing HV battery to body with battery powered drill .
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    Note
    8x patch bolts, E12, 38 Nm, Install new patch bolts, Do not over tighten bolts, Torque at later step.
  10. Install bolts securing LH side of HV battery to body with battery powered drill .
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    Note
    8x patch bolts, 13mm, 55 Nm, Install new patch bolts, Do not over tighten bolts, Torque at later step.
  11. Install bolts securing RH side of HV battery to body with battery powered drill .
    Informational PurposesAn informational icon, calling your attention
    Note
    8x patch bolts, 13mm, 55 Nm, Install new patch bolts, Do not over tighten bolts, Torque at later step.
  12. Torque bolts securing HV battery to body on both side.
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    Note
    16x patch bolts, 13mm, 55 Nm.
  13. Torque remaining HV battery bolts.
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    Note
    8x bolts, E12, 38 Nm, 2x bolts, 21mm, 115 Nm, 4x bolts, 13mm, 30 Nm.
  14. Raise vehicle off of HV battery.
  15. Install inner center HV battery bolts with battery powered drill .
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    Note
    4x patch bolts, E12, 38 Nm, Install new patch bolts, Do not over tighten bolts.
  16. Torque the inner center HV battery bolts.
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    Note
    4x patch bolts, E12, 38 Nm.
  17. Install LH ski side covers.
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    Note
    14x clips, 3x covers.
  18. Install RH ski side covers.
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    Note
    14x clips, 3x covers.
  19. Install front bash plate extrusion.
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    Note
    2x bolts, T30, 16 Nm.
  20. Install mid aero shield.
    Informational PurposesAn informational icon, calling your attention
    Note
    20x bolts, 10mm, 4 Nm, 2x push clips.
  21. Install LH rear shear plate.
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    Note
    3x screws, T25, 6 Nm, 1x bolt, 10mm, 4 Nm, 2x push pins, Install new nyloc nut 15mm, 35 Nm.
  22. Install RH rear shear plate.
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    Note
    3x screws, T25, 6 Nm, 1x bolt, 10mm, 4 Nm, 2x push pins, Install new nyloc nut 15mm, 35 Nm.
  23. Lower vehicle fully.
  24. Connect first responder loop and then 12V negative terminal.
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    Note
    1x connector, 1x nut, 10mm, 5 Nm.
  25. Connect first responder loop.
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    Note
    1x connector.
  26. Install HEPA filter housing.
  27. Install underhood storage unit.
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    Note
    10x bolts, 10mm, 4 Nm, 10x bolts, 10mm, 7 Nm.
  28. Install frunk carpet.
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    Note
    2x connectors.
  29. Install under hood aprons.
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    Note
    4x aprons.
  30. Close hood.
  31. Calibrate falcon doors using MCU.
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    Note
    Required after 12V and FRL disconnect.
  32. Close LH front door.
  33. Remove vehicle from lift.
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    Note
    Lower rack arms fully and move them from under vehicle, Remove air suspension from "Jack Mode".