2025-10-20

Pack Contactor - High Voltage - Positive (Remove and Replace)

Correction code 1630012112 FRT 1.20 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.

  • 2025-10-20: Added steps for removing and installing the passthrough to provide more room for maneuvering the contactor.
  • 2025-06-18: Updated title and FRT
  • 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 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.
Table 1. Torque Specifications:Pack Contactor - High Voltage - Positive (Remove and Replace)
Description Torque Value Recommended Tools Reuse/Replace Notes
Bolt securing positive pack contactor to positive busbar
9 Nm (6.6 lbs-ft)
  • Insulated Ratchet 1/4in Dr Std
  • Insulated Extension 1/4in Dr. x 6in
  • Insulated Socket 1/4in Dr. 6pt. Std. x 13mm
  • Electrical Protective Gloves
  • Class 0 Electrical Protective Gloves
 Replace 1104475-00-F
Nut securing positive pack contactor to HV battery tall terminal to module 4 rear terminal
9 Nm (6.6 lbs-ft)
  • Insulated Ratchet 1/4in Dr Std
  • Insulated Extension 1/4in Dr. x 6in
  • Insulated Socket 1/4in Dr. 6pt. Std. x 13mm
  • Electrical Protective Gloves
  • Class 0 Electrical Protective Gloves
 Replace 1104654-00-B
Nuts securing positive pack contactor to ancillary bay
8 Nm (5.9 lbs-ft)
  • TORQUE WRENCH, 1/4" DR. MICROMETER
  • Electrical Protective Gloves
  • WOBBLE EXTENSION, EXT .10.5\' NARROW 1/4DIA
  • SKT, 1/4" SQ DR, 10MM, UNIV, HV INSULATED
  • Class 0 Electrical Protective Gloves
  • RATCHET, 0.25IN SQ DR, HV INSULATED
  • PICK-UP MAGNET WITH PLASTIC HANDLE, 18" FLEXIBLE
 Reuse
Warning IconA warning icon, calling your attention to a possibly risky situation
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.

Remove

  1. Remove the pyrotechnic battery disconnect. See Pyro Disconnect - HV Battery (Remove and Replace).
  2. Lift HV Controller up.
  3. Disconnect PCS to DC bus HV connector.
    Informational PurposesAn informational icon, calling your attention
    Note
    Release the locking tab by pulling upward.
  4. Disconnect PCS logic connector from PCS.
  5. Remove the DCDC passthrough from the ancillary bay. See Passthrough - DCDC - 12V (Remove and Replace).
  6. Disconnect ancillary bay harness connectors from negative pack contactor.
  7. Remove ancillary bay harness clip from positive pack contactor.
  8. Remove HV joint insulators from positive HV switch.
  9. Remove bolt securing positive pack contactor to positive busbar.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Insulated Ratchet 1/4in Dr Std
    • Insulated Extension 1/4in Dr. x 6in
    • Insulated Socket 1/4in Dr. 6pt. Std. x 13mm
    • Electrical Protective Gloves
    • Class 0 Electrical Protective Gloves
  10. Remove and discard nut securing positive pack contactor to module 4 rear terminal.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Insulated Ratchet 1/4in Dr Std
    • Insulated Extension 1/4in Dr. x 6in
    • Insulated Socket 1/4in Dr. 6pt. Std. x 13mm
    • Electrical Protective Gloves
    • Class 0 Electrical Protective Gloves
  11. Remove nuts securing positive pack contactor to ancillary bay.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • TORQUE WRENCH, 1/4" DR. MICROMETER
    • Electrical Protective Gloves
    • WOBBLE EXTENSION, EXT .10.5\' NARROW 1/4DIA
    • SKT, 1/4" SQ DR, 10MM, UNIV, HV INSULATED
    • Class 0 Electrical Protective Gloves
    • RATCHET, 0.25IN SQ DR, HV INSULATED
    • PICK-UP MAGNET WITH PLASTIC HANDLE, 18" FLEXIBLE
  12. Detach the positive pack contactor from the guide pins (x2), then remove it from the ancillary bay.

Install

  1. Position positive pack contactor to ancillary bay for installation.
  2. Install the nuts (x3) that attach the positive pack contactor to the ancillary bay, and mark after torque.
    8 Nm (5.9 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • TORQUE WRENCH, 1/4" DR. MICROMETER
    • Electrical Protective Gloves
    • WOBBLE EXTENSION, EXT .10.5\' NARROW 1/4DIA
    • SKT, 1/4" SQ DR, 10MM, UNIV, HV INSULATED
    • Class 0 Electrical Protective Gloves
    • RATCHET, 0.25IN SQ DR, HV INSULATED
    • PICK-UP MAGNET WITH PLASTIC HANDLE, 18" FLEXIBLE
    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 bolt securing positive pack contactor to positive busbar.
    9 Nm (6.6 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Insulated Ratchet 1/4in Dr Std
    • Insulated Extension 1/4in Dr. x 6in
    • Insulated Socket 1/4in Dr. 6pt. Std. x 13mm
    • Electrical Protective Gloves
    • Class 0 Electrical Protective Gloves
  4. Install nut securing positive pack contactor to HV battery tall terminal to module 4 rear terminal.
    9 Nm (6.6 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Insulated Ratchet 1/4in Dr Std
    • Insulated Extension 1/4in Dr. x 6in
    • Insulated Socket 1/4in Dr. 6pt. Std. x 13mm
    • Electrical Protective Gloves
    • Class 0 Electrical Protective Gloves
  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 HV joint insulators onto positive pack contactor.
  9. Install ancillary bay harness clip to positive pack contactor.
  10. Connect ancillary bay harness connectors to positive pack contactor.
  11. Install the DCDC passthrough to the ancillary bay. See Passthrough - DCDC - 12V (Remove and Replace).
  12. Connect PCS to DC bus HV connector.
    Informational PurposesAn informational icon, calling your attention
    Note
    Push connector downward then push the locking tab downward to install connector, make sure the connector is fully seated.
  13. Lower HV Controller back into place.
  14. Install the pyrotechnic battery disconnect. See Pyro Disconnect - HV Battery (Remove and Replace).
  15. Raise all windows and close all doors.