2025-10-23

Contactor - Fast Charge - HV Battery (Remove and Replace)

Correction code 1630010122 FRT 1.74 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.

  • 2025-10-23: Torque values in Installation step 2 corrected.
Equipment:
  • 1076921-00-A Fluke 1587
  • 1059330-00-B Skt, 1/4in Dr, 5-Lobe Torx Plus External
  • 1057602-00-A Ratchet, 1/4" Sq Dr, HV Insulated
  • 1467483-00-C M3/Y Ancillary Bay Service Insulator Kit
  • 1131071-00-A Dummy Disconnect, Pyro, Safety
  • 1057605-00-A Skt, 1/4" Dr, 10mm, Univ, HV Insu
  • 1453448-01-A Kit Digital Multimeter Set EXTECH 335
  • 1076928-00-A Test Probes - Hioki 9461
  • 1133768-00-C Insulated Socket 1/4in Dr. 12pt. Deep x 10mm
  • 1108272-00-B Cap, Logic Conn, Inv, 3DU
  • 1057606-00-A Skt, 1/4" Sq Dr, 13mm, HV Insulated
  • 1076927-00-A Hioki tester
Table 1. Torque Specifications: Contactor - Fast Charge - HV Battery (Remove and Replace)
Description Torque Value Recommended Tools Reuse/Replace Notes
Patch bolts that attach the DC link negative busbar, the DC link positive busbar, and the positive inlet 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
Bolts that attach the fast charge contactor to the lower fast charge insulator assembly
5.5 Nm (4.1 lbs-ft)
  • Socket External Torx 1/4in Dr. E8
 Reuse

Remove

  1. Remove the negative inlet fast charge busbar. See Busbar - Fast Charge - Input - Negative (Remove and Replace).
  2. Remove and discard the patch bolts (x3) that attach the DC link negative busbar, the DC link positive busbar, and the positive inlet fast charge busbar to the fast charge contactor.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 13 mm socket
    • Torque wrench with angle measurement
  3. Remove the bolts (x3) that attach the fast charge contactor to the lower fast charge insulator assembly.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Socket External Torx 1/4in Dr. E8

Install

  1. Install the bolts (x3) that attach the fast charge contactor to the lower fast charge insulator assembly.
    5.5 Nm (4.1 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    Mark after torque.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Socket External Torx 1/4in Dr. E8
  2. Install and torque the new patch bolts (x3) that attach the DC link negative busbar, the DC link positive busbar, and the positive inlet fast charge busbar to the fast charge contactor to the first value, then loosen the bolts by 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
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 13 mm socket
    • Torque wrench with angle measurement
  3. Install the negative inlet fast charge busbar. See Busbar - Fast Charge - Input - Negative (Remove and Replace).