2026-08-09

Pack Contactor - High Voltage - Positive (Model Y L) (Remove and Replace)

Correction code 16300121102 FRT 1.68 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.

  • 2026-06-05: Released new procedure.
Equipment:
  • 1076927-00-A HIOKI RM 3548
  • 1076928-00-A TEST PROBES - HIOKI 9461
  • 1453448-02-A TOOL, KIT DIGITAL MULTIMETER SET
Warning
Remove all jewelry (watches, bracelets, rings, necklaces, earrings, ID tags, piercings, etc.) from your person, and all objects (keys, coins, pens, pencils, tools, fasteners, etc.) from your pockets before performing any procedure that exposes you to high voltage.
Warning
If corrective eyewear is necessary to safely perform any procedure, make sure that the eyewear is securely restrained to the head and cannot fall off.
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.

Torque Specifications

Table 1. Torque Specifications:Pack Contactor - High Voltage - Positive (Model Y L) (Remove and Replace)
Description Torque Value Recommended Tools Reuse/Replace Notes
Bolt that attaches the positive pack contactor to the positive busbar
5 Nm (3.7 lbs-ft) + 60 degrees
  • SKT, 1/4" SQ DR, 13MM, HV INSULATED
 Replace 1104475-00-F
Nut that attaches the positive pack contactor to the HV battery tall terminal
5 Nm (3.7 lbs-ft) + 35 degrees
  • SKT, 1/4" SQ DR, 13MM, HV INSULATED
 Replace 1104654-00-A
Nuts (x3) that attach the positive pack contactor to the ancillary bay
8 Nm (5.9 lbs-ft)
  • Insulated Socket 1/4in Dr. 12pt. Deep x 10mm
 Reuse

Remove

  1. Remove the pyro disconnect. See Pyro Disconnect - HV Battery (Model Y L) (Remove and Replace).
    Warning
    HV insulating gloves and leather glove protectors must be worn throughout the remainder of this procedure. Do not remove gloves or protectors until otherwise noted.
  2. Remove the ancillary bay harness clip from the positive pack contactor.
  3. Disconnect the ancillary bay harness connectors (x2) to the positive pack contactor.
  4. Remove the HV joint insulators (x2) from the positive pack contactor.
  5. Remove and discard the bolt that attaches the positive pack contactor to the positive busbar.
    Tip
    Use of the following tool(s) is recommended:
    • SKT, 1/4" SQ DR, 13MM, HV INSULATED
  6. Remove and discard the nut that attaches the positive pack contactor to the HV battery tall terminal.
    Tip
    Use of the following tool(s) is recommended:
    • SKT, 1/4" SQ DR, 13MM, HV INSULATED
  7. Remove the nuts (x3) that attach the positive pack contactor to the ancillary bay.
    Tip
    Use of the following tool(s) is recommended:
    • Insulated Socket 1/4in Dr. 12pt. Deep x 10mm
  8. Release the guide pins (x2) that attach the positive pack contactor to the ancillary bay.

Replace

  1. Secure the guide pins (x2) that attach the positive pack contactor to the ancillary bay.
  2. Install the nuts (x3) that attach the positive pack contactor to the ancillary bay.
    8 Nm (5.9 lbs-ft)
    Tip
    Use of the following tool(s) is recommended:
    • Insulated Socket 1/4in Dr. 12pt. Deep x 10mm
  3. Install new bolt that attaches the positive pack contactor to the positive busbar.
    5 Nm (3.7 lbs-ft) + 60 degrees
    Note
    Mark after torque.
    Tip
    Use of the following tool(s) is recommended:
    • SKT, 1/4" SQ DR, 13MM, HV INSULATED
  4. Install new nut that attaches the positive pack contactor to the HV battery tall terminal.
    5 Nm (3.7 lbs-ft) + 35 degrees
    Note
    Mark after torque.
    Tip
    Use of the following tool(s) is recommended:
    • SKT, 1/4" SQ DR, 13MM, HV INSULATED
  5. Measure the resistance at the HV joint between the HV battery positive pack contactor and the center of the HV battery positive terminal.
    Note
    The reading must be 73 μΩ or less.
  6. Measure the resistance at the HV joint between the HV battery positive pack contactor and the center of the DC link positive busbar.
    Note
    The reading must be 30 μΩ or less.
  7. Install HV joint insulators (x2) from positive pack contactor.
  8. Install the ancillary bay harness clip to the positive pack contactor.
  9. Connect the ancillary bay harness connectors (x2) to the positive pack contactor.
  10. Install the pyro disconnect. See Pyro Disconnect - HV Battery (Model Y L) (Remove and Replace).
    Warning
    HV insulating gloves and leather glove protectors must be worn throughout the remainder of this procedure. Do not remove gloves or protectors until otherwise noted.