2026-05-29

HV Battery (AWD) (Remove and Replace)

Correction code 16010202 4.92 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.

Warning IconA warning icon, calling your attention to a possibly risky situation
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.
  • 2025-07-01: Released new procedure.
Equipment:
  • 1936724-00-A - Universal Lift Pad Adapters
  • 1133787-00-A Key, Seat Belt Release, Model 3
  • 1020566-00-F ASY, Battery Table, Manual Lift
  • 1020566-99-A Top Plate, Battery Table, Manual Lift
  • 1129166-00-A Hoist, H-Frame EMEA
  • 1073363-00-A Gantry, Adjustable, Aluminum
  • 1134523-00-A Kit, Alignment Rods, Battery, Model 3
  • 1140311-00-A Lever Lock, HV Connector, Model 3
  • 1053600-00-B Drive Unit Pressure Test Fixture
  • 1130942-00-B Adapter, Coolant Reservoir Pressure Test
  • 1132185-00-B Kit, Coolant Leak Test Adapters, Model 3
  • 1133843-00-A Kit, Coolant Drain & Fill Adapters, M3
  • 1135762-00-A Kit, Svc Plug, Cooling Hose, Model 3
  • GSN-TL-000564 Kit, Battery Coolant Drain and Fill
  • 1026636-00-A Pack Enclosure Leak Tester, HV Battery
  • 1140501-00-A Pack Kit, Enclosure, Leak Test, HV Battery, Complete
  • 1144879-00-A Kit, Encl Leak Test Adapters, HV Battery
  • 1108272-00-B Cap, Logic Conn, Inv, 3DU

Torque Specifications

Table 1. Torque Specifications:HV Battery (AWD) (Remove and Install) / HV Battery (AWD) (Remove and Replace)
Description Torque Value Recommended Tools Reuse/Replace Notes
LH/RH middle/rear inner HV battery bolt.
66 Nm (48.7 lbs-ft)
  • 3/8 inch ratchet with rotary disc changeover RTCH-REV-3/8IN-72TEETH-L175MM ZEBRA
  • 16 mm deep socket
  • 3 in extension
 Reuse
LH /RH front inner HV battery bolts
136 Nm (100.3 lbs-ft)
  • Torx Plus EP20 socket
  • 1/2 inch reversible ratchet wrench with rotary disc reverse RTCH-REV-1/2IN-72TEETH-250MM ZEBRA
  • EXT, 1/2" DR, 6
 Reuse
Nut (X1) securing DCDC ground busbar to HV battery
9 Nm (6.6 lbs-ft)
  • Class 00 Electrical Protective Gloves
  • 13 mm socket
  • 4 in extension
  • RATCHET, 1/4" DR, M12, BARE TOOL
 Replace
Bolt (X1) securing front drive unit HV harness to front drive unit
10 Nm (7.4 lbs-ft)
  • 10 mm socket
  • Class 00 Electrical Protective Gloves
  • Electrical Protective Gloves
 Replace
Front drive unit ground strap bolt from HV battery
10 Nm (7.4 lbs-ft)
  • Ratcheting Combination wrench Flex head 10mm
 Reuse
Nut (X1) securing rear drive unit HV cable bracket to HV battery.
10 Nm (7.4 lbs-ft)
  • 10 mm socket
  • DRIVER KIT, 1/4" HEX, M12
 Reuse
Bolt securing LH/RH side of subframe to body
125 Nm (92.2 lbs-ft)
  • 21 mm socket
  • Cordless Ratchet/Impact Driver
 Reuse
Central bolts (X4) securing HV battery center ski cover
34 Nm (25.1 lbs-ft)
  • External Torx Plus EP14
  • Cordless Ratchet/Impact Driver
  • 3 in extension
 Reuse
Bolts securing LH/RH front support bracket to vehicle
110 Nm (81.1 lbs-ft)
  • Cordless Ratchet/Impact Driver
  • 16 mm deep socket
  • 1/2 inch socket wrench hexagon short SKTWRNCH-1/2IN-SHORT-HEX-WS16 ZEBRA
 Reuse
LH /RH bolts securing HV battery to vehicle
35 Nm (25.8 lbs-ft)
  • 13 mm socket
  • Cordless Ratchet/Impact Driver
  • 3 in extension
 Reuse

Remove

  1. Remove the HV battery. See HV Battery (AWD) (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.
    Informational PurposesAn informational icon, calling your attention
    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.
    Informational PurposesAn informational icon, calling your attention
    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 lift the H-frame off of the old HV battery.

Install

  1. Open the crate top that houses the new HV battery pack.
  2. Remove the nuts (x4)that attach the new HV battery to the crate.
  3. Position the HV battery crate under the gantry and secure the H-frame to the HV battery.
  4. Lift the new HV battery out of the crate
  5. Move HV battery table underneath the gantry.
  6. Lower the HV battery onto the battery table.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure to align HV battery onto 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 attach 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
  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.
    Informational PurposesAn informational icon, calling your attention
    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. Raise the gantry and H-frame from the old HV battery.
  16. Lower gantry and remove the H-frame from the gantry.
  17. Install the nuts (x4) that attach the HV battery to the crate hand tight.
  18. Close the crate that housed the old HV battery.
  19. Install the HVC logic cap onto the new HV battery.
  20. Install the penthouse engagement seal onto the HV battery pack.
    Informational PurposesAn informational icon, calling your attention
    Note
    This seal is a one time use item and should be replaced each time a HV battery pack is removed from vehicle or installed onto a new HV battery pack if not equipped.
  21. Install the HV battery. See HV Battery (AWD) (Remove and Install)
  22. Connect LV battery maintenance charger.
    Informational PurposesAn informational icon, calling your attention
    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.
    Informational PurposesAn informational icon, calling your attention
    Note
    Select Service mode plus > High Voltage
  25. Select "Software Reinstall" through the touchscreen.
    Informational PurposesAn informational icon, calling your attention
    Note
    Software Reinstall > CAN ECU > Reinstall, Allow routine to complete, ensure routine is successful
  26. Select "High Voltage Battery Replacement" through the touchscreen.
    Informational PurposesAn informational icon, calling your attention
    Note
    Procedures > High Voltage Battery Replacement.
  27. SelectHigh Voltage Battery Replacement Routine > Run to allow the routine to complete, then select Close.
  28. SelectThermal > Actions > Stop Thermal Fill/Drain to allow the routine to complete.
  29. SelectThermal > Coolant System > Coolant Purge Start to 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.
  30. Disconnect the LV maintainer from the vehicle.
  31. Exit Service Mode Plus. See Service Mode Plus