2024-11-11

Passthrough - DCDC - 12V (Remove and Replace)

Correction code 1601010102 FRT 1.14 NOTE: Unless otherwise explicitly stated in the procedure, the above correction code and FRT reflect all of the work required to perform this procedure, including the linked procedures. Do not stack correction codes unless explicitly told to do so. NOTE: See Flat Rate Times to learn more about FRTs and how they are created. To provide feedback on FRT values, email LaborTimeFeedback@tesla.com. NOTE: See Personal Protection to make sure wearing proper PPE when performing the below procedure.

Warning IconA warning icon, calling your attention to a possibly risky situation
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.
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Warning
If corrective eyewear is necessary to safely perform any procedure, make sure that the eyewear is securely restrained to the head and cannot fall off.
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 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.

Torque Specifications

Table 1. Torque Specifications: Passthrough - DCDC - 12V (Remove and Replace)
Description Torque Value Recommended Tools Reuse/Replace Notes
Nut that attaches the DCDC ground busbar to HV battery
9 Nm (6.6 lbs-ft)
  • 13 mm socket
  • Ratchet/torque wrench
  • 4 in extension
 Replace 1523698-00-A
Bolts that attach the DCDC passthrough to ancillary bay
10 Nm (7.4 lbs-ft)
  • Insulated Ratchet/torque wrench
  • External Torx E10 5-Lobe
 Reuse

Remove

  1. Remove the pyrotechnic battery disconnect. See Pyro Disconnect - HV Battery (Remove and Replace).
  2. Disconnect the Power Conversion System (PCS) LV connector from the PCS.
    Informational PurposesAn informational icon, calling your attention
    Note
    Lift the HVC up from the front side.
    Informational PurposesAn informational icon, calling your attention
    Note
    Pull upward to release the locking tab. Use a plastic trim tool to help lift the connector upward as needed.
  3. Remove and discard the nut that attaches the DCDC ground busbar to HV battery.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 13 mm socket
    • Ratchet/torque wrench
    • 4 in extension
  4. Gently lift the DCDC ground busbar upwards.
  5. Remove the bolts that attach the DCDC passthrough to ancillary bay.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Insulated Ratchet/torque wrench
    • External Torx E10 5-Lobe
  6. Remove the DCDC passthrough from the ancillary bay.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Pay special attention to avoid metal damage to the cable insulation layer.

Install

  1. Position the DCDC passthrough to the ancillary bay for installation.
  2. Install the bolts that attach the DCDC passthrough to ancillary bay.
    10 Nm (7.4 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Insulated Ratchet/torque wrench
    • External Torx E10 5-Lobe
  3. Gently press down the DCDC ground busbar to HV battery.
  4. Install a new nut that attaches the DCDC ground busbar to HV battery.
    9 Nm (6.6 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 13 mm socket
    • Ratchet/torque wrench
    • 4 in extension
  5. Connect the PCS LV connector to the PCS.
    Informational PurposesAn informational icon, calling your attention
    Note
    Push the connector downward then push the locking tab downward to install the connector. Make sure the connector is fully seated.
  6. Install the pyrotechnic battery disconnect. See Pyro Disconnect - HV Battery (Remove and Replace).