2025-10-20

Shunt - HV Battery (Remove and Replace)

Correction code 1630012502 FRT 1.08 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 ServiceManualFeedback@tesla.com. NOTE: See Personal Protection to make sure wearing proper PPE when performing the below procedure. NOTE: See Ergonomic Precautions for safe and healthy working practices.

  • 2025-06-04: Added instruction to zero adjust the Hioki resistance meter prior to measurement.
    • 2025-10-20: Updated the routine for different shunt types.
  • 1057602-00-A Ratchet, 1/4" Sq Dr, HV Insulated
  • 1057606-00-A Skt, 1/4" Sq Dr, 13mm, HV Insulated
  • 1131071-00-A Dummy Disconnect, Pyro, Safety
  • 1108272-00-B Cap, Logic Conn, Inv, 3DU
  • 1076927-00-A Resistance meter, microohm, Hioki RM 3548
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.
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Warning

Only technicians who have completed all required certification courses are permitted to perform this procedure. Tesla recommends third party service provider technicians undergo equivalent training before performing this procedure. For more information on Tesla Technician requirements, or descriptions of the subject matter for third parties, see HV Certification Requirements. 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: Shunt - HV Battery (Remove and Replace)
Description Torque Value Recommended Tools Reuse/Replace Notes
Bolt that secures the HV battery shunt to ancillary bay
9 Nm (6.6 lbs-ft)
  • Insulated tools:
    • 13 mm socket
    • Ratchet/torque wrench
 Replace

Remove

  1. Remove the ancillary bay. See Cover - Ancillary Bay (Remove and Replace).
  2. Remove the pyro disconnect from ancillary bay. See Pyro Disconnect - HV Battery (Remove and Replace).
  3. Install pyro disconnect dummy.
  4. Disconnect shunt assembly connector.
  5. Release harness from shunt insulator.
  6. Remove shunt insulator.
  7. Remove bolt securing shunt assembly to penthouse.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Insulated tools:
      • 13 mm socket
      • Ratchet/torque wrench
  8. Remove pyro disconnect dummy.
  9. Remove shunt assembly from penthouse.

Install

  1. Use an IPA wipe to clean the HV mating surfaces of the shunt, busbar, and the pyrotechnic battery disconnect.
  2. Position shunt assembly to penthouse for installation.
    Informational PurposesAn informational icon, calling your attention
    Note
    Write down new shunt bar resistance and Part Number, As written on shunt sticker, Resistance Value should be close to 20000 - 30000.
  3. Loosely install bolt securing shunt assembly to penthouse.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Insulated tools:
      • 13 mm socket
      • Ratchet/torque wrench
  4. Set the multimeter to the "LoZ" (low impedance) mode.
    Informational PurposesAn informational icon, calling your attention
    Note
    For Fluke multimeters without "LoZ" mode on the mode selector, see Multimeter (LoZ Setting).
  5. Install the pyro disconnect to ancillary bay. See Pyro Disconnect - HV Battery (Remove and Replace).
  6. Tighten a new bolt that attaches the HV battery shunt to the ancillary bay.
    9 Nm (6.6 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Insulated tools:
      • 13 mm socket
      • Ratchet/torque wrench
  7. Perform a zero adjust of the Hioki resistance meter. See Resistance Meter (Zero Adjust).
  8. Use the Hioki resistance meter to measure the resistance at the HV joint between the pyrotechnic battery disconnect and the LH busbar.
    Informational PurposesAn informational icon, calling your attention
    Note
    The maximum acceptable resistance is 0.048 mΩ (48 μΩ). There is too much resistance in the High Voltage joint. Remove the fastener, clean areas with isopropyl alcohol, install fastener back and test again
  9. Use the Hioki resistance meter to measure the resistance at the HV joint between the pyrotechnic battery disconnect and the shunt.
    Informational PurposesAn informational icon, calling your attention
    Note
    The maximum acceptable resistance is 0.033 mΩ (33 μΩ). There is too much resistance in the High Voltage joint. Remove the fastener, clean areas with isopropyl alcohol, install fastener back and test again
  10. Use the Hioki resistance meter to measure the resistance of the HV joint between the shunt and the adjacent busbar.
    Informational PurposesAn informational icon, calling your attention
    Note
    The maximum acceptable resistance is 0.045 mΩ (45 μΩ). There is too much resistance in the High Voltage joint. Remove the fastener, clean areas with isopropyl alcohol, install fastener back and test again
  11. Install shunt insulator.
  12. Install harness to shunt insulator.
  13. Connect shunt assembly connector.
  14. Remove service insulator kit and HVC logic cap.
  15. Install the ancillary bay. See Cover - Ancillary Bay (Remove and Replace).
  16. Enable Service Mode Plus. See Toolbox 3 (Connect and Disconnect).
  17. SelectHigh Voltage > Procedures > Shunt Replacement > Continue > Write Shunt Data and WRITE operation, enter the shunt bar resistance value previously recorded in step 2, and select corresponding shunt type based on the Part number. Click Run and allow the routine to complete.
    Informational PurposesAn informational icon, calling your attention
    Note
    Shunt types includes Vishay whose part number looks like 2084224-XX-X and Cyntec whose part number looks like 1078835-XX-X or 1588177-XX-X.
  18. Exit Service Mode Plus. Connect a laptop with Toolbox 3 to the vehicle. See Toolbox 3 (Connect and Disconnect).
  19. Install HEPA filter assembly. See Toolbox 3 (Connect and Disconnect).