2025-06-04

Busbar - Fast Charge Contactor To Direct Current Busbar - Negative (Remove and Replace)

Correction code 1630010102 FRT 1.44 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.

  • 2025-06-04: Added instruction to zero adjust the Hioki resistance meter prior to measurement.
  • 1057605-00-A Skt, 1/4" Dr, 10mm, Univ, HV Insu
  • 1076928-00-A Test Probes - Hioki 9461
  • 1453448-01-A Kit Digital Multimeter Set EXTECH 335
  • 1076927-00-A Hioki tester
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.
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
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.

Remove

  1. Remove the pyrotechnic battery disconnect. See Pyro Disconnect - HV Battery (Remove and Replace).
  2. Disconnect ancillary bay harness connectors from negative pack contactor.
  3. Remove the HV joint insulators (x2) from the negative pack contactor.
  4. Remove and discard the patch bolt that attaches the negative pack contactor to the DC link busbar joint.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
  5. Remove and discard the patch nut that attaches negative pack contactor to the HV battery tall silicon terminal.
  6. Remove the nuts (x3) that attach the negative pack contactor to the ancillary bay.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use insulated magnet to retrieve the nuts after removal. The number of nuts on newer vehicles may vary.
  7. Remove the guide pins (x2) to remove the negative pack contactor from the ancillary bay.

Install

  1. Position the negative pack contactor to the ancillary bay for installation, and then install the guide pins (x2).
  2. Install the nuts (x3) that attach the negative pack contactor to the ancillary bay, and mark after torque.
    9 Nm (6.6 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    Use insulated magnet as needed to position the nuts onto the studs. The number of nuts on newer vehicles may vary.
  3. Install the patch bolt that attaches the negative pack contactor to the DC link busbar joint, and mark after torque.
  4. Install the patch nut that attaches negative pack contactor to the HV battery tall silicon terminal.
  5. Perform a zero adjust of the Hioki resistance meter. See Resistance Meter (Zero Adjust).
  6. Perform Hioki impedance test at the HV joint of the negative pack contactor to the negative DC link busbar.
    • If the resistance is greater than 0.060 mΩ (60 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.
    • If the resistance is less than 0.020 mΩ (20 μΩ), reposition the probes and measure again.
  7. Perform Hioki impedance test at the negative pack contactor to module 1 rear terminal
    Informational PurposesAn informational icon, calling your attention
    Note
    The acceptable impedance is 110 μΩ or less.
  8. Install the HV joint insulators (x2) to the negative pack contactor.
  9. Connect the ancillary bay harness connectors (x2) to the negative pack contactor.
  10. Install the pyrotechnic battery disconnect. See Pyro Disconnect - HV Battery (Remove and Replace).
  11. Raise all windows and close all doors.