20/06/2022 14:10:36

HV Harness - Rapid Splitter to FJB - Small Drive Unit (Remove and Replace)

Correction Code 44503202

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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.
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Note
This procedure only applies to vehicles built after April 10, 2016.

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

  1. Remove the rear subframe assembly. See Small RDU.
  2. Remove the HV battery. See HV Battery (AWD) (Remove and Install).
  3. Remove the bolts (x2) that attach the LV rapid mate bracket to the body of the vehicle (torque 7 Nm).
  4. Release the clips that attach the HV harness to the LV rapid mate, and then put the LV rapid mate aside.
  5. Remove the barrel clip that attaches the HV cables to the body of the vehicle.
  6. Remove and discard the bolts (x2) that attach the HV cable guide bracket to the body of the vehicle (torque 8 Nm).
  7. Remove the B- HV cable from the Rapid Splitter:
    1. Use a screwdriver or pick to release the black 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 the tool 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 special tool, remove it.
    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. If present, remove and discard the spring from the end of the HV cable.
    7. If present, remove the retaining ring from the end of the B- cable.
    8. 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
    9. Inspect the plastic cap for damage. Replace if damaged.
    10. Place an HV cover on the end of the HV cable.
  8. 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.
  9. Remove the push clips (x3) that attach the front part of the RH rear wheel arch liner.
  10. Move the rear wheel arch liner away for access.
  11. Disconnect the S8 parking sensor.
  12. Release the clips (x2) that attach the HV cable to the body of the vehicle.
  13. Remove the RH front wheel (refer to procedure).
  14. Remove the push clips (x6) and nut (torque 6 Nm) that attach the rear portion of the RH front wheelhouse liner to the vehicle, and then move it aside for access.
  15. If equipped, remove the bolts (x4) that attach the side sill closing panel to the wheel well (torque 25 Nm).
  16. Remove the nuts (x3) that attach the HV cable bracket to the studs on the body of the vehicle (torque 4 Nm).
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    Note
    Type and number of fasteners may vary.
  17. Disconnect the electrical connector from the following:
    • Powertrain coolant pump 1
    • Suspension level sensor
  18. Working from the wheel well, use an extension to release the screws (x4) that attach the HV cables to the forward junction box (FJB) (torque 7 Nm).
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    Note
    Components have been removed in this graphic to aid clarity.
  19. Working from the rear RH wheel well, secure the HV cables to the nylon fish tape tool using a string or fishing line.
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    Note
    The nylon fish tape tool is used to pull and route the new harness through the channel during installation.
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    Note
    Secure both HV cables together and slightly staggered to reduce the likelihood of one of them getting caught in the channel.
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    Note
    The following image shows the HV cables without the protective caps installed.
  20. Gently pull the HV harness towards the front of the vehicle and through the channel.
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    CAUTION
    Ensure that the string or fishing line is not accidentally released from the HV cables while pulling them through the channel.
  21. Once the HV cables are all the way through the channel, release the string or fishing line from the cables, but do not pull the nylon fish tape tool back through the channel or remove it from the vehicle.
  22. Remove the HV cables from the vehicle.

Installation

Installation procedure is the reverse of removal, except for the following:

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CAUTION
Replace all patchbolt(s).
  1. Install protective caps over both HV cables to protect the terminals and seals when pulling the harness through the channel.
  2. Attach the new HV harness to the nylon fish tape tool using string or fishing line and, from the rear RH wheel arch, gently pull the front of the nylon fish tape tool through the channel towards the rear of the vehicle and retrieve the HV harness.
  3. Apply P-80 emulsion to the connector seals on the HV cables before securing the HV cables to the FJB.
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    CAUTION
    Do not apply P-80 emulsion to the HV terminals.
  4. Install new O-rings on the HV cables:
    1. Place the seal installation tool over the terminal.
    2. Apply P-80 emulsion to the seal installation tool.
    3. Push the O-ring along the seal installation tool until it slides onto the HV cable.
    4. Remove the seal installation tool from the HV cable.
    5. Perform steps a-d on the other HV cable.
  5. Install both B+ and B- collars unto the end of the FJB HV cable
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    Note
    Make sure that the B+ and B- colors match the RED and BLACK color on the HV cable.
  6. Install the retaining rings onto the end of the B+ and B- HV cables
  7. Use the installation tool to install both locking collars in the Rapid Splitter.
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    Note
    Install both locking collars into the Rapid Mate before installing either of the HV cables.
  8. Use the flare nut crowfoot wrench at 90 degrees from the torque wrench when torquing the collar (torque 35 Nm).
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    CAUTION
    If the flare nut crowfoot wrench is not 90 degrees from the torque wrench, it can damage the special tool and/or the Rapid Splitter.
  9. After inserting the new HV cables into the Rapid Splitter, perform pull test to ensure that the cables are correctly installed.
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    Note
    The HV cables must be pulled with a force of 150N.