2026-05-28

HV Battery (RWD) (Remove and Replace)

Correction code 16010102 4.68 NOTE: Unless otherwise explicitly stated in the procedure, the correction code and FRT listed above 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. NOTE: See Personal Protection to make sure you are wearing proper PPE when performing the procedure below. NOTE: See Ergonomic Precautions for safe and healthy working practices.

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Warning
This procedure is a DRAFT. Although it has been validated, Warnings and Cautions might be missing. Follow safety requirements and use extreme caution when working on or near High Voltage systems and components.
  • 2026-05-28: Add a note to perform pack visual inspection during installation.
  • 2026-05-21: Added warnings to never move the gantry with a suspended load or put any part of the body underneath a suspended load. Changed wording to clarify that crates are positioned under gantries rather than gantries moved over crates.
  • 2025-07-10: Released new procedure.

Remove

  1. Remove the HV battery. See HV Battery (RWD) (Remove and Install)
  2. If the HV battery is being shipped, attach the old pyrotechnic battery disconnect to the brackets on the ancillary bay cover of the old HV battery using cable ties. If the ancillary bay cover is not equipped with brackets, attach the old pyrotechnic battery disconnect to the RH rear corner of the old HV battery using cable ties.
    Informational PurposesAn informational icon, calling your attention
    Note
    Put a piece of paper under the pyrotechnic battery disconnect. Use masking tape if necessary to prevent movement.
    Figure 1. Pyrotechnic battery disconnect attached to brackets on the ancillary bay cover
    Figure 2. Pyrotechnic battery disconnect attached to RH rear corner of HV battery
  3. Attach HV battery H-frame to the gantry and raise it into position.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    Never stand or place any part of your body underneath a suspended load.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    Never attempt to move a gantry while a load is suspended.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    Refer to the gantry manufacturer's instructions for safety and operational information.
  4. Position the HV battery under the gantry.
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    Note
    Assistance recommended. If the original pack is RWD and supplied pack is DM, center ski transfer is required.
  5. Lower H-frame onto the old HV battery and secure the H-frame to the HV battery.
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    Note
    6x bolts, 8mm Allen, Hand tight
  6. Raise the old HV battery off the battery table.
  7. Position a pallet under the gantry.
  8. Lower the HV battery onto the pallet.
  9. Remove H-frame from the old HV battery.
  10. Use the gantry to raise the H-frame off of the old HV battery.

Install

  1. Open the crate top housing the new HV battery pack.
  2. Remove nuts that attach the new HV battery to the crate.
    Informational PurposesAn informational icon, calling your attention
    Note
    4x nuts, 15mm
  3. Position the new HV battery crate under the gantry and secure the H-frame to the battery.
    Informational PurposesAn informational icon, calling your attention
    Note
    Perform a visual inspection of the bolt holes and HV headers to make sure that terminals are aligned and threads are not damaged before installing a bolt or mating a connector.
    Informational PurposesAn informational icon, calling your attention
    Note
    6x bolts, 8mm Allen, Hand tight
  4. Lift the new HV battery out of the crate.
  5. Move the HV battery crate from under the gantry, then position the HV battery table under the gantry.
  6. Lower the HV battery onto the battery table.
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    Note
    Make sure to align the HV battery onto the center ski.
  7. Release the H-frame from the HV battery and raise the gantry.
    Informational PurposesAn informational icon, calling your attention
    Note
    6x bolts, 8mm Allen, Hand tight
  8. Remove the HV battery from under the gantry.
  9. Position the old HV battery under the gantry.
  10. Lower the H-frame onto the old HV battery and secure the H-frame to the HV battery.
    Informational PurposesAn informational icon, calling your attention
    Note
    6x bolts, 8mm Allen, Hand tight
  11. Raise the old HV battery above the HV battery crate.
  12. Position the HV battery crate underneath the old HV battery.
  13. Lower the old HV battery into the crate.
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    Note
    Use caution to align the 4 studs and not damage the battery.
  14. Remove the H-frame from the old HV battery.
    Informational PurposesAn informational icon, calling your attention
    Note
    6x bolts, 8mm Allen, Hand tight
  15. Use the gantry to lift the H-frame off of the old HV battery.
  16. Lower the gantry and remove the HV battery H-frame from the gantry.
  17. Install the nuts that attach the HV battery to the crate hand tight.
    Informational PurposesAn informational icon, calling your attention
    Note
    4x nuts, 15mm
  18. Close the crate top housing the old HV battery.
  19. Install HVC logic cap onto the new HV battery.
  20. Install penthouse engagement seal onto the HV battery pack.
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    Note
    This seal is a one time use item and should be replaced each time an HV battery pack is removed from the vehicle or installed onto a new HV battery pack if not equipped.
  21. Install the HV battery. See HV Battery (RWD) (Remove and Install)
  22. Connect LV battery maintenance charger.
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    Note
    Release the positive terminal cover. Attach the positive terminal to the jump post. Attach the negative terminal to the ground terminal located above the VCfront. Connect the maintainer to power supply. To avoid damaging the vehicle. DO NOT allow the positive cable to make contact with other metal components. Never have a float charger and the LV battery simultaneously connected for any extended period of time (apart from during a SW reinstall/CAN redeploy).
  23. Enable Service Mode Plus. See Service Mode Plus
  24. Access High Voltage System routines using the touchscreen.
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    Note
    Select Service mode plus > High Voltage
  25. Select "High Voltage Battery Replacement" through the touchscreen.
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    Note
    Procedures > High Voltage Battery Replacement.
  26. Select "Software Reinstall" through the touchscreen.
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    Note
    Software Reinstall > CAN ECU > Reinstall, Allow routine to complete, ensure routine is successful
  27. Disconnect the LV maintainer from the vehicle.
  28. Exit Service Mode.