2026-09-11

Controller - High Voltage (7-Seat) (Remove and Replace)

Correction code 16301652 FRT 1.44 NOTE: Unless otherwise explicitly stated in the procedure, the correction code and its associated 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. 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.

  • 2026-09-09: Released new procedure.
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.
CAUTION
When servicing the ancillary bay cover and components in or around the ancillary bay, there is a possibilty of encountering metal flashing on the inner edge of the vehicle single-piece rear casting. These sharp protrusions are a cut hazard, and proper PPE should be worn if there is a chance of contacting the flashing unprotected. If not already wearing leather over gloves, then at least wear cut-resistant gloves when the flashing is present.
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. Open all four doors and lower all four windows.
  2. Remove the LH and RH lower C-pillar trim. See Trim - C-Pillar - Lower - LH (7 Seat) (Remove and Replace).
  3. Remove the 2nd row seats. See Seat Assembly - 2nd Row - LH (7-Seat) (Remove and Replace) and Seat Assembly - 2nd Row - RH (7-Seat) (Remove and Replace).
  4. Remove the 3rd row seat cushion and the LH and RH seat cushion bolsters. See Bolster - Seat Cushion - 3rd Row - LH (Remove and Replace).
  5. Remove the 3rd row carpet. See Carpet - 3rd Row (Remove and Replace).
  6. Disconnect the LV power. See 12V/LV Power (Disconnect and Connect).
  7. Remove the 3rd row NVH insulator. See NVH Insulator - 3rd Row Seat (Remove and Replace).
  8. Remove all items from pockets and ensure not wearing metal items.
  9. Inspect HV insulating gloves.
    Note
    Check gloves for damage prior to use, Refer to service document TN-15-92-003 R1, for information on inspecting HV gloves.
  10. Put on HV insulating gloves, leather outer gloves, and safety glasses.
    Warning
    Continue to wear the gloves until instructed to remove them.
  11. Remove the ancillary bay probe cover. See Cover - HV Probe - HV Battery (Remove and Replace).
  12. Use a multimeter to probe the voltages.
    Warning
    In order to limit potential exposure to high voltage, measure for high voltage in the order specified below.
    Measurement Order

    Component Test

    B+

    (Probe opening closer to HV DC connector)

    B-

    (Probe opening, closer to HV Processor Logic connector)

    GND

    Measured Voltage less than 10 V

    Measured Voltage 10 V or more
    1

    HV battery positive contactor

    Positive (+) Lead

    Negative (-) Lead on ancillary bay cover

    Pass

    Fail

    HV battery positive contactor might be seized. SeeHV Battery Contactor Seize Check.
    2

    HV battery negative contactor

    Positive (+) Lead

    Negative (-) Lead on ancillary bay cover

    Pass

    Fail

    HV battery negative contactor might be seized. SeeHV Battery Contactor Seize Check.
    3

    HV

    Positive (+) Lead

    Negative (-) Lead

    Pass

    Fail

    Perform a HV battery contactor seize check. SeeHV Battery Contactor Seize Check.
    Tip
    Use of the following tool(s) is recommended:
    • Electrical Protective Gloves
    • Slim Test Probes - 1130480-02-B
    • Fluke 1587 - 1076921-00-A
    Figure 1. B+ to Ground measurement
    Figure 2. B- to Ground measurement
    Figure 3. B+ to B- measurement
  13. Install the ancillary bay probe cover. See Cover - HV Probe - HV Battery (Remove and Replace).
  14. Remove the ancillary bay cover. See Cover - Ancillary Bay (7-Seat) (Remove and Replace).
  15. Inspect the ancillary bay for any missing insulators and install service insulator kit before continuing to next step.
    Note
    The number of bolts on newer vehicles may vary.
  16. Remove the pyrotechnic battery disconnect. See Pyrotechnic Battery Disconnect (Remove and Replace).
  17. Disconnect the high voltage controller connectors (x7).
  18. Remove the bolts (x2) that attach the high voltage controller to the high voltage controller tray, and then remove the high voltage controller from the vehicle.
    Note
    Use of the following tool(s) is recommended:
    • Insulated Ratchet/torque wrench
    • Insulated 4 in extension
    • External Torx E6
    • Electrical Protective Gloves

Install

  1. Position the high voltage controller on the high voltage controller tray, and then install the bolts that attach the controller to the tray.
    2 Nm (1.5 lbs-ft)
    Note
    Use of the following tool(s) is recommended:
    • Insulated Ratchet/torque wrench
    • Insulated 4 in extension
    • External Torx E6
    • Electrical Protective Gloves
  2. Connect the high voltage controller connectors (x7).
  3. Install the pyrotechnic battery disconnect. See Pyrotechnic Battery Disconnect (Remove and Replace).
  4. Install the ancillary bay cover. See Cover - Ancillary Bay (7-Seat) (Remove and Replace).
  5. Install the 3rd row NVH insulator. See NVH Insulator - 3rd Row Seat (Remove and Replace).
  6. Connect the LV power. See 12V/LV Power (Disconnect and Connect).
  7. Install the 3rd row carpet. See Carpet - 3rd Row (Remove and Replace).
  8. Install the 3rd row seat cushion and the LH and RH seat cushion bolsters. See Bolster - Seat Cushion - 3rd Row - LH (Remove and Replace).
  9. Install the 2nd row seats. See Seat Assembly - 2nd Row - LH (7-Seat) (Remove and Replace) and Seat Assembly - 2nd Row - RH (7-Seat) (Remove and Replace).
  10. Install the LH and RH lower C-pillar trim. See Trim - C-Pillar - Lower - LH (7 Seat) (Remove and Replace).
  11. Raise the LH front window and close the LH front door.