2026-10-12

Busbar - Fast Charge Contactor to DC Bus - Positive (Remove and Replace)

Correction code 1630010072 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.

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.
  • 2026-10-09: Updated the torque data for the bolt that attaches the positive fast charge busbar to the fast charge contactor and added additional Hioki impedance tests.
  • 2026-08-12: Reorganized the procedure per the latest validation.

Torque Specifications

Table 1. Torque Specifications: Busbar - Fast Charge Contactor to DC Bus - Positive (Remove and Replace)
Description Torque Value Recommended Tools Reuse/Replace Notes
Bolt that attaches the busbar cover access door
9 Nm (6.6 lbs-ft)
  • 10 mm 12-point deep socket
 Reuse
Bolts that attach the charge port busbar kit to the HV header
9 Nm (6.6 lbs-ft)
  • 10 mm 12-point deep socket
 Reuse
Patch bolts that attach the negative and the positive fast charge busbar DC link sides
  • Torque the bolt to
    10 Nm (7.4 lbs-ft)
  • Loosen the bolt by 180°
  • Retorque the bolt to
    10 Nm (7.4 lbs-ft)
  • 13 mm socket
  • Torque wrench with angle measurement
 Replace 1104475-00-F
Patch bolt that attaches the positive fast charge busbar to the fast charge contactor
15 Nm (11.1 lbs-ft) - 180 degrees
5 Nm (3.7 lbs-ft) + 60 degrees
  • 13 mm socket
  • Torque wrench with angle measurement
 Replace 1084662-00-C
Bolts that attach the fast charge assembly to the ancillary bay
5.5 Nm (4.1 lbs-ft)
  • 10 mm socket
 Reuse
Patch bolt that attach the positive fast charge busbar to the fast charge contactor
15 Nm (11.1 lbs-ft) - 180 degrees
  • 13 mm socket
  • Torque wrench with angle measurement
 Replace

Remove

  1. Open all doors and lower all windows.
  2. Move both front seats forward.
  3. Disconnect the LV battery power. See LV Power (Disconnect and Connect) (Modify).
  4. Remove the 2nd row seat cushion bracket. See Bracket - Edge Support - Seat Cushion - 2nd Row - LH (Remove and Replace).
  5. Verify the operation of the multimeter.
    Note
    Set the multimeter to DC voltage. Confirm the multimeter is properly measuring voltage by testing the 16v battery.
  6. Perform the Vehicle HV Disablement Procedure. See Vehicle HV Disablement Procedure (Test/Adjust).
  7. Remove the bolt that attaches the busbar cover access door.
    Tip
    Use of the following tool(s) is recommended:
    • 10 mm 12-point deep socket
  8. Remove the bolts (x2) that attach the charge port busbar kit to the HV header.
    Tip
    Use of the following tool(s) is recommended:
    • 10 mm 12-point deep socket
  9. Remove the A/C charge port inlet harness clip.
  10. Lift the busbar kit connector and shift the rear end of the busbar assembly upward to remove the aluminum connector housing from the HV header.
  11. Position the charge port busbar connector on the cross-member in front of the ancillary bay for access.
  12. Remove the ancillary bay cover. See Ancillary Bay Cover (Remove and Replace).
  13. Remove the pyrotechnic battery disconnect. See Pyro Disconnect - HV Battery (Remove and Replace).
  14. Install the pyrotechnic disconnect dummy.
  15. Remove the ancillary bay harness clip around the negative pack contactor area.
  16. Press the tabs on both sides by hand, and lift the connector upwards to disconnect the LV fast charge contactor connector.
  17. Disconnect the connector that attaches the power conversion system to the A/C harness.
    Note
    Release the locking tab by pulling upward. Use plastic trim tool to help lift the connector upward as needed.
  18. Release the locking tab to remove the A/C filter harness from the fast charge contactor cover.
  19. Remove the harness clips (x2) from the fast charge contactor cover.
    Note
    Move the wiring harness around the fast charge cover aside.
  20. Remove the ancillary bay left terminals cover.
  21. Remove and discard the patch bolts (x2) that attach the negative and the positive fast charge busbar DC link sides.
    Tip
    Use of the following tool(s) is recommended:
    • 13 mm socket
    • Torque wrench with angle measurement
  22. Remove Busbar DC input assembly from ancillary bay. See Header - Busbar DC Input (Remove and Replace).
  23. Remove the bolts (x2) that attach the fast charge assembly to the ancillary bay.
    Tip
    Use of the following tool(s) is recommended:
    • 10 mm socket
  24. Remove the guide pins (x2) to remove the fast charge assembly from the ancillary bay.
  25. Release the clips (x8) and the alignment pin to remove and discard the fast charge insulator cover from the fast charge assembly.
  26. Remove and discard the patch bolt that attach the positive fast charge busbar to the fast charge contactor, and then remove and discard the positive fast charge busbar.
    Tip
    Use of the following tool(s) is recommended:
    • 13 mm socket
    • Torque wrench with angle measurement

Install

  1. Install and torque a new patch bolt that attaches the positive fast charge busbar to the fast charge contactor to the first value, then loosen the bolt by 180 degrees, and then torque to the final value.
    • Torque the bolt to
      10 Nm (7.4 lbs-ft)
    • Loosen the bolt by 180°
    • Retorque the bolt to
      10 Nm (7.4 lbs-ft)
    Tip
    Use of the following tool(s) is recommended:
    • 13 mm socket
    • Torque wrench with angle measurement
  2. Perform a Hioki impedance test at the positive HV joints of the fast charge contactor on the DC link busbar and inlet busbar.
    Note
    Perform a zero adjust to the Hioki meter prior to testing. See Resistance Meter (Zero Adjust)
    • If the resistance is greater than 0.040 mΩ (40 μΩ), there is too much resistance in the High Voltage joint. Remove the fastener, clean the areas with isopropyl alcohol, install the fastener back and test again.
  3. Install the clips (x8) and the alignment pin to install the new fast charge insulator cover to the fast charge assembly.
  4. Position the fast charge assembly to the ancillary bay, and then secure the guide pins (x2).
  5. Install the bolts (x2) that attach the fast charge assembly to the ancillary bay.
    5.5 Nm (4.1 lbs-ft)
    Note
    Mark after torque.
    Tip
    Use of the following tool(s) is recommended:
    • 10 mm socket
  6. Install Busbar DC input assembly to ancillary bay and perform the Hioki resistance test. See Header - Busbar DC Input (Remove and Replace).
  7. Install new patch bolts (x2) that attach the negative and the positive fast charge busbar DC link sides to the first value, then loosen 180 degrees, and then torque to the final value.
    15 Nm (11.1 lbs-ft) - 180 degrees
    5 Nm (3.7 lbs-ft) + 60 degrees
    Note
    Mark after torque.
    Tip
    Use of the following tool(s) is recommended:
    • 13 mm socket
    • Torque wrench with angle measurement
  8. Perform Hioki impedance test at the positive and the negative HV joints of the fast charge busbar DC link side.
    Note
    The resistance at the positive and negative HV joint should be 60 𝜇Ω or less.
  9. Install the insulator for the DC input assembly.
    Note
    2x tabs, 1x datum
  10. Connect the megaharness connector to the DC input assembly.
  11. Install the bolts that attach the positie and negative fast charge busbars at the DC link side.
    15 Nm (11.1 lbs-ft) - 180 degrees
    5 Nm (3.7 lbs-ft) + 60 degrees
    Torque each bolt to the first value, then loosen it by 180 degrees, then torque the bolt to the final value.

    Positive busbar

    Negative busbar

  12. Perform a Hioki test at the positive HV joint of the fast charge busbar at the DC link side.
    Note
    The resistance at the positive HV joint at the DC link side should be 25 𝜇Ω or less.
  13. Perform a Hioki test at the negative HV joint of the fast charge busbar at the DC link side.
    Note
    The resistance at the negative HV joint at the DC link side should be 40 𝜇Ω or less.
  14. Install the ancillary bay left terminals cover.
  15. Install the harness clips (x2) to the fast charge contactor cover.
  16. Connect the LV fast charge connector.
  17. Attach the locking tab to install the AC filter harness to the fast charge contactor cover.
  18. Connect the connector that attaches the power conversion system to the A/C harness.
    Note
    Push the connector downward, and then push the locking tab downward to install the connector. Make sure the connector is fully seated.
  19. Install the ancillary bay harness clip around the negative pack contactor area.
  20. Install the pyrotechnic battery disconnect. See Pyro Disconnect - HV Battery (Remove and Replace).
    Note
    Stop this step after inspecting the ancillary bay walls and cover seal for damage.
  21. Position the ancillary bay cover to the HV battery.
    Note
    Ensure all accessible insulators are present.
  22. Use IPA wipes to clean the HV connector contact surface and the busbar HV connector contact surface of the residual Penetrox.
    Note
    Allow 1 minute dry time for each surface. The new busbar comes with the penetrox applied to the HV connector. It is necessary to clean the HV connector during the re-use of the busbar.
  23. Apply 2 drops of Penetrox A-13 about 5mm in diameter to either side of the hole on both leads on the HV connector joints, and then spread the liquid evenly until the contact surface is fully covered.
  24. Position the busbar kit connector and lower it onto the HV header.
    Note
    Shift the rear end of the busbar assembly upward to help ease installation. If excessive force is required to seat the busbar, they may have been bent. Inspect for damage and replace if necessary.
  25. Install the A/C charge port inlet harness clip.
  26. Install the bolts (x2) that attach the charge port busbar kit to the HV header.
    9 Nm (6.6 lbs-ft)
    Note
    On 3-phase vehicles, also connect the AC charging interface connector.
    Tip
    Use of the following tool(s) is recommended:
    • 10 mm 12-point deep socket

    AC Charging Interface Connector

  27. Perform Hioki resistance test at each HV joint from the HV busbar lead to the bolt head.
    Note
    The acceptable resistance is between 0.050 mΩ (50 μΩ) and 0.195 mΩ (195 μΩ).
    • If the resistance is greater than 0.195 mΩ (195 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 lower than 0.050 mΩ (50 μΩ), reposition the probes and measure again.
    • If the resistance is repeatedly between 0.00 mΩ and 0.050 mΩ (50 μΩ), Hioki test passed, proceed to the next step.
  28. Install the bolt that attaches the busbar cover access door.
    9 Nm (6.6 lbs-ft)
    Tip
    Use of the following tool(s) is recommended:
    • 10 mm 12-point deep socket
  29. Install the ancillary bay cover. See Ancillary Bay Cover (Remove and Replace).
    Note
    Before installing the ancillary bay cover, inspect the ancillary bay cover seal and confirm there is no visual damage. If the seal is torn and/or delaminated, replace the ancillary bay cover.
  30. Install the 2nd row seat cushion bracket. See Bracket - Edge Support - Seat Cushion - 2nd Row - LH (Remove and Replace).
  31. Connect the LV battery power. See LV Power (Disconnect and Connect) (Modify).
  32. Move the front seats back to their original position.
  33. Raise all windows and close the doors.