2025-03-12

HIGH VOLTAGE HARNESS - FRONT DRIVE UNIT (Remove and Replace)

Correction code 4450010402 FRT 1.00 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

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: HIGH VOLTAGE HARNESS - FRONT DRIVE UNIT (Remove and Replace)
Description Torque Value Recommended Tools Reuse/Replace Notes
Bolts (x6) that attach the center ski cover to the HV battery
34 Nm (25.1 lbs-ft)
  • External Torx Plus EP14
 Reuse
Bolt that attaches the front drive unit HV harness to the front drive unit
10 Nm (7.4 lbs-ft)
  • 10 mm socket
 Reuse

Remove

  1. Perform the vehicle HV disablement procedure. See Vehicle HV Disablement Procedure.
  2. Remove the front HV battery skid plate. See FRONT SKID PLATE (Remove and Replace).
  3. Remove the bolt that attaches the front drive unit HV harness to the front drive unit.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 10 mm socket
  4. Slide the red release tab to unlock the front drive unit HV harness connector, and then slowly unlatch the release handle on the front drive unit HV harness connector, and then disconnect the connector from the front drive unit.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not apply excessive force to the handle; doing so could damage the connector alignment tabs.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure that the alignment tabs on the front drive unit header are not damaged.
  5. Remove the front drive unit harness from the casting, and then move the harness aside.
  6. Disconnect the AC compressor HV harness connector.
    Informational PurposesAn informational icon, calling your attention
    Note
    Disengage the red locking tab by pulling it away from the connector, then depress the orange tab and pull the connector outward, and then depress the green tab to release the connector.
  7. Remove the clips (x2) that attach the ancillary harness bracket to the front of HV battery.
  8. Remove the rear HV battery skid plate. See High Voltage Battery Assembly - Skid Plate - Rear (Remove and Replace).
  9. Position a coolant drain container underneath the RH rear of the HV battery.
  10. Disconnect the RH coolant hose from the rear of HV battery, and plug the ends of fittings as soon as possible to avoid coolant loss.
  11. Remove the coolant drain container from underneath the RH rear of the HV battery.
  12. Disconnect the AC HV harness connector from the right rear of HV battery.
    Informational PurposesAn informational icon, calling your attention
    Note
    Release the red tab before releasing the black locking lever.
  13. Release the clips (x2) that attach the HV battery return tube to the rear of the battery.
  14. Release the locking tab, rotate the lever up to disengage the connector, and then disconnect the front drive unit HV cable from the rear of the HV battery.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not apply excessive force to the handle; doing so could damage the connector alignment tabs.
  15. With assistance, remove the bolts (x6) that attach the center ski cover to the HV battery.
    Informational PurposesAn informational icon, calling your attention
    Note
    The bolts at both ends are short bolts and the bolts in the middle are long.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • External Torx Plus EP14
  16. Remove the upper cap covers from both sides of the center ski cover. See Bracket - High Voltage - Ski - Top (Remove and Replace).
  17. Remove the front drive unit HV harness.

Install

  1. Position the front drive unit HV harness onto the HV battery center ski.
    Informational PurposesAn informational icon, calling your attention
    Note
    Ensure that the installation direction is consistent with the arrow direction on the center ski cover.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use a plastic trim tool to press the harness into the groove, if necessary.
  2. Install the upper cap covers to both sides of the center ski cover. See Bracket - High Voltage - Ski - Top (Remove and Replace).
  3. With assistance, install the bolts (x6) that attach the center ski cover to the HV battery.
    34 Nm (25.1 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    The bolts at both ends are short bolts and the bolts in the middle are long.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • External Torx Plus EP14
  4. Slowly latch the release handle while pressing the front drive unit HV harness connector into the LH rear of the HV battery.
    Informational PurposesAn informational icon, calling your attention
    Note
    Once connected, verify that the locking tab is not damaged and the front drive unit HV connector is fully secured in the latched position.
  5. Install the clips (x2) that attach the HV battery return tube to the rear of the battery.
  6. Connect the AC HV harness connector to the right rear of HV battery.
    Informational PurposesAn informational icon, calling your attention
    Note
    Hold the connector level with header and secure with even upward force. Rotate the lever arm and secure locking tab. Verify that the latch is fully secured and not damaged.
  7. Position a coolant drain container underneath the RH rear of the HV battery.
  8. Remove the plugs on the ends of fittings, and then connect the RH coolant hose to the rear of HV battery.
    Informational PurposesAn informational icon, calling your attention
    Note
    Perform a push-pull-push test to make sure that the hose is fully secured.
    Informational PurposesAn informational icon, calling your attention
    Note
    Coolant loss greater than 1L requires vacuum fill.
  9. Remove the coolant drain container from underneath the RH rear of the HV battery.
  10. Install the rear HV battery skid plate. See High Voltage Battery Assembly - Skid Plate - Rear (Remove and Replace).
  11. Install the clips (x2) that attach the ancillary harness bracket to the front of HV battery.
  12. Connect the AC compressor HV harness connector.
    Informational PurposesAn informational icon, calling your attention
    Note
    After the connector is seated and there is an audible click, push the red locking tab to double-lock the connector.
  13. Install the HV connector lever lock to the front drive unit HV cable connector.
  14. Install the front drive unit harness to the casting.
  15. Align the connector to the front drive unit, and then remove the HV connector lever lock before fully latching the connector.
  16. Slowly latch the release handle while pressing the front drive unit HV harness connector into the front drive unit.
    Informational PurposesAn informational icon, calling your attention
    Note
    Once connected, verify that the locking tab is not damaged and the front drive unit HV connector is fully secured in the latched position.
  17. Install the bolt that attaches the front drive unit HV harness to the front drive unit.
    10 Nm (7.4 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 10 mm socket
  18. Install the front HV battery skid plate. See FRONT SKID PLATE (Remove and Replace).
  19. Install the 2nd row seat cushion. See 2ND ROW SEAT CUSHION (Remove and Replace).
  20. Connect the LV battery power. See LV Power (Disconnect and Connect).
  21. Unlock the vehicle gateway. See Gateway (Unlock).
  22. On the touchscreeen, touch Service Mode > Thermal > Coolant System > Coolant Purge Start and select Run to start the "Coolant Air Purge" routine, and allow the routine to complete.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure vehicle is not in Drive, shifting the vehicle into Drive will stop this routine. The test will last approximately 10 mins. The test will vary speeds from 3500-6500 RPM (idle speed = ~1500 RPM) and actuate the valve between series and parallel. If speed hovers at 7000 RPM, it indicates the pump is air locked, perform the vacuum fill again. Continue to add coolant and purge until the coolant level reaches between the NOM and MAX Lines on the bottle.
  23. Exit Service Mode. See Service Mode.
  24. Inspect the coolant level and top off as necessary, and then install the coolant bottle cap.
    Informational PurposesAn informational icon, calling your attention
    Note
    Ensure that the coolant level is at the "Max" line.
  25. Install the HEPA filter assembly. See HEPA FILTER (Remove and Replace).